CROSS-REFERENCES TO RELATED APPLICATIONS
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
BACKGROUND OF THE INVENTION
1. Field of the invention
[0003] The invention relates to a fluid application system for mixing a chemical with a
diluent and spraying a mixture of the chemical and the diluent.
2. Description of the Related Art
[0004] Various spraying devices are known in which a chemical is mixed into a carrier fluid
and then a mixture of the chemical and carrier fluid is sprayed through a nozzle.
For example,
U.S. Patent Application Publication No. 2010/0282776 describes a handheld device where a manual pump assembly draws diluent (e.g., water)
from a reservoir and the diluent is moved through a venturi which draws liquid concentrate
from a container into the diluent forming a diluted concentrate. The diluted concentrate
is then sprayed through a nozzle.
WO 03/011473 discloses a device for dispensing liquids that is adapted to mix a secondary liquid
with a primary diluent liquid and discharge the mixture through a nozzle.
[0005] What is needed is an alternative fluid application system that can accept a container
having a concentrated chemical, create a mixture of the chemical and a diluent, and
spray the diluted concentrate through a nozzle.
SUMMARY OF THE INVENTION
[0006] The foregoing needs can be met with a fluid application system according to the invention.
The fluid application system mixes a chemical with a diluent and sprays a mixture
of the chemical and the diluent.
[0007] In one embodiment, a fluid application system for mixing a chemical with a diluent
and spraying a mixture of the chemical and the diluent according to claim 1 is provided.
Optional features thereof are defined in claims 1 to 9.
[0008] In another embodiment, a method for spraying one or more mixtures of one or more
chemicals is provided according to claim 10. Optional features thereof are defined
in claim 11.
[0009] The fluid application system provides a means for dispensing concentrated formula
at a reduced, but predetermined, level of chemical concentration. The fluid application
system can automatically blend a diluent with a concentrated formula to achieve proper
performance.
[0010] The fluid application system can accurately blend two products by means of displacement
via system of conduit, metering orifices and check valves.
[0011] The fluid application system incorporates a fluid transfer model that is designed
to (1) deliver a pre-determined amount of concentrate mixed with a given amount of
diluent (target ratio) (2) by using a displacement pump ranging from 0.8-1.6 grams
displacement pump and a (3) pre-disposed metering orifice.
[0012] The fluid application system uses a refill in the form of a replaceable vessel that
is constructed to manage the contents to provide proper flow of product and venting
of the head-space throughout the life of the refill. The refill protects the contents
from user intervention by incorporating an aerosol-type valve as a closing device.
The valve incorporates a metering orifice so that every refill is automatically distributed
at the correct dilution. The valve incorporates a means for replacing headspace at-or-greater-than
the rate at which the concentrate is removed. The valve incorporates a means for eliminating
"bottle paneling" due to concentrate reaction with head-space. The valve automatically
vents headspace should formula release gas, such as a gas released from hydrogen peroxide.
[0013] The refill valve architecture provides means of attachment/release as well as ensure
communication link between the displacement device and refill contents. The refill
accommodates a single-direction means of retention with mechanical means of refill
release for replacement. The refill provides a docking system that insures a liquid-tight
communication link to a formula. The refill incorporates variable tension means that
communicate docking is complete, ensures that seal surfaces remain intact and serve
as means of disengagement when the refill requires replacement.
[0014] These and other features, aspects, and advantages of the present invention will become
better understood upon consideration of the following detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015]
Figure 1 is a top, right, front perspective view of a fluid application system that
is not claimed.
Figure 2 is a cross-sectional view of the fluid application system of Figure 1 taken
along line 2-2 of Figure 1.
Figure 3 is a detailed front right perspective view of the sprayer component of the
fluid application system of Figure 1 taken along line 3-3 of Figure 2.
Figure 4 is a detailed cross-sectional view of the manifold, diluent reservoir, and
chemical concentrate container of the fluid application system of Figure 1 taken along
line 4-4 of Figure 2.
Figure 5 is a right, rear perspective view of the chemical concentrate container of
the fluid application system of Figure 1.
Figure 6 is a cross-sectional view of the chemical concentrate container of the fluid
application system taken along line 6-6 of Figure 5.
Figure 7 is a top, right, front perspective view of the fluid application system of
Figure 1 with one shell of the sprayer housing removed showing the chemical concentrate
container being installed into the fluid application system.
Figure 8 is a detailed cross-sectional view, similar to Figure 2, of the sprayer component
of another example of a fluid application system that is not claimed.
Figure 9 is a top, right, front perspective view of an embodiment of a fluid application
system in accordance with the invention.
Figure 10 is a cross-sectional view of the fluid application system of Figure 9 taken
along line 10-10 of Figure 9.
Figure 11 is a detailed cross-sectional view of the sprayer component of the fluid
application system of Figure 9 taken along line 11-11 of Figure 10.
Figure 12 is a detailed cross-sectional view of the manifold, diluent reservoir, and
chemical concentrate container of the fluid application system of Figure 9 taken along
line 12-12 of Figure 10.
Figure 13 is a detailed cross-sectional view of the manifold of the fluid application
system of Figure 9 taken along line 12-12 of Figure 10.
Figure 14 is a top, right, rear perspective view of the fluid application system of
Figure 9 showing the chemical concentrate container being installed into the fluid
application system.
Figure 15 is a right, rear perspective view of the diluent reservoir of the fluid
application system of Figure 9.
Figure 16 is a top, right perspective view of one embodiment of the chemical concentrate
container of Figure 9 with a duckbill valve.
Figure 17 is a cross-sectional view of the chemical concentrate container of Figure
16 in a closed position taken along line 17-17 of Figure 16.
Figure 18 is a top, right perspective view of another embodiment of the chemical concentrate
container of Figure 9 with a two-way valve.
Figure 19 is a top, right perspective view of the chemical concentrate container of
Figure 18 with the umbrella valve removed to reveal the fluid flow path.
Figure 20 is a cross-sectional view of the chemical concentrate container of Figure
18 in a closed position taken along line 20-20 of Figure 18.
Figure 21 is a top, right perspective view of yet another embodiment of the chemical
concentrate container of Figure 9 with a permeable two way valve.
Figure 22 is a cross-sectional view of the chemical concentrate container of Figure
21 in a closed position taken along line 22-22 of Figure 21.
Figure 23 is a cross-sectional view of still another embodiment of the chemical concentrate
container of Figure 9 with a flexible inner bag.
Figure 24 is a cross-sectional detailed view of a valve system of the chemical concentrate
container of Figures 16 and 17 taken along line 17-17 of Figure 16.
Figure 25 is a right side perspective view of another embodiment of a fluid application
system in accordance with the invention.
Figure 26 is a front perspective view of the fluid application system of Figure 25.
Figure 27 is a rear perspective view of the fluid application system of Figure 25.
Figure 28 is a bottom perspective view of the fluid application system of Figure 25.
Figures 29A-C are schematic diagrams of additional fluid application systems and containers
in accordance with the invention.
Figure 30 is a plot of results from a theoretical analysis of the fluid application
system of Figure 25.
Figures 31A-C are schematic diagrams of various scenarios analyzed in the theoretical
analysis of the fluid application system of Figure 25.
Figure 32 is a right side perspective view of an experimental testing prototype of
the fluid application system in Figure 25.
Figures 33A-C are plots illustrating the dynamic changes in center of gravity of the
fluid application system of Figure 25.
Figure 34 is a detailed view of one embodiment of a chemical concentrate container
for the fluid application system of Figure 25.
Figure 35 is a close-up view of a mounting cup and valve assembly of the chemical
concentrate container of Figure 34.
Figure 36 is a schematic diagram of a flow restriction area of the chemical concentrate
container of Figure 34.
Figure 37 is a close-up view of the flow restriction area of the chemical concentrate
container of Figure 34.
Figure 38 shows the fluid geometry and boundary conditions used in a Computational
Fluid Dynamics (CFD) analysis performed on a fluid application system of the invention.
[0016] Like reference numerals will be used to refer to like parts from Figure to Figure
in the following detailed description.
DETAILED DESCRIPTION OF THE INVENTION
[0017] Looking at Figures 1 to 7, there is shown an example of a fluid application system
10 that is not claimed and is presented for illustration purposes only. The fluid
application system 10 includes a sprayer housing 12 having a first shell 13 and a
second shell 14 that can be fastened together with screws or another suitable fastening
device. The sprayer housing 12 surrounds a sprayer assembly 110 that will be described
in detail below.
[0018] The fluid application system 10 includes a diluent reservoir 16 which in one non-limiting
version holds about sixteen fluid ounces. Water is the preferred diluent, but any
other fluid suitable for diluting a concentrated liquid chemical can be used as the
diluent. The diluent reservoir 16 can be formed from a suitable material such as polymeric
material (e.g., polyethylene or polypropylene). The diluent reservoir 16 has an outlet
neck 17 that terminates in a peripheral flange 18. A diluent reservoir cap 20 having
an outer circular wall 21 with an inner lower rib 22 is installed on the neck 17 of
the diluent reservoir 16 with the rib 22 engaging the flange 18 of the cap 20. The
diluent reservoir cap 20 has a central well 24 that is in fluid communication with
an inlet port 25 of the diluent reservoir cap 20. A dip tube holder 26 is press fit
over the end of the inlet port 25. A one way valve, which is duckbill valve 28 in
this example, is positioned between the well 24 and the dip tube holder 26. A diluent
dip tube 29 is press fit into the dip tube holder 26. The duckbill valve 28 allows
fluid flow from the diluent dip tube 29 toward the well 24, and prevents flow from
the well 24 back toward the diluent dip tube 29. Alternative one way valves are also
suitable for use in the dip tube holder 26 such as a ball valve. It is contemplated
that the one way valve is located in or adjacent an opening of the diluent reservoir
16 to prevent flow upstream toward an intake end of the diluent dip tube 29 in the
diluent reservoir 16.
[0019] The diluent reservoir 16 has a fill opening 31 that allows the diluent reservoir
16 to be refilled with diluent. A refill cap 33 covers the fill opening 31 after refilling.
A vent opening 34 is located in the refill cap 33, and an umbrella valve 35 controls
venting from the interior of the diluent reservoir 16 to ambient atmosphere. The diluent
reservoir 16 has outer wall 36 with a protruding ridge 37.
[0020] A fluid manifold 40 is located within the sprayer housing 12 of the fluid application
system 10. The manifold 40 has a main body 42 that defines a mixing chamber 43. The
manifold 40 has an outlet port 44 that is in fluid communication with the mixing chamber
43 and a mixed fluid supply conduit 45. A fluid stream comprising a mixture of the
diluent and chemical is provided from the manifold to the mixed fluid supply conduit
45 to a sprayer assembly as described below.
[0021] The manifold 40 has a diluent inlet port 46 having a cylindrical outer wall 47 that
defines a diluent inlet 48 of the manifold 40. An O-ring 49 is provided on the outside
of the outer wall 47 of the diluent inlet port 46. As shown in Figure 4, the diluent
inlet port 46 is assembled in the well 24 of the diluent reservoir cap 20 with the
O-ring 49 providing a seal thereby placing the inlet port 25 of the diluent reservoir
cap 20 in fluid communication with the diluent inlet 48 of the manifold 40.
[0022] The manifold 40 also has a chemical inlet port 51 in fluid communication with the
mixing chamber 43. The chemical inlet port 51 has an outer wall 52 that defines a
chemical inlet 53 of the manifold 40. A valve body 55 is assembled into the chemical
inlet port 51. The valve body 55 has an inwardly protruding wall 56 that supports
a spring-biased valve stem 57 having a central passageway 58 with a slit 59 that allows
for fluid flow from the central passageway 58 to the chemical inlet 53 of the manifold
40 when the slit 59 is uncovered by upward movement of the valve stem 57.
[0023] The fluid application system 10 includes a chemical concentrate container 61 which
in one non-limiting version holds about six fluid ounces. The concentrate can be selected
such that when the concentrate is diluted with the diluent, any number of different
fluid products is formed. Non-limiting example products include general purpose cleaners,
kitchen cleaners, bathroom cleaners, dust inhibitors, dust removal aids, floor and
furniture cleaners and polishes, glass cleaners, anti-bacterial cleaners, fragrances,
deodorizers, soft surface treatments, fabric protectors, laundry products, fabric
cleaners, fabric stain removers, tire cleaners, dashboard cleaners, automotive interior
cleaners, and/or other automotive industry cleaners or polishes, or even insecticides.
The chemical concentrate container 61 can be formed from a suitable material such
as polymeric material (e.g., polyethylene or polypropylene), and in certain examples,
the chemical concentrate container 61 comprises a transparent material that allows
the user to check the level of chemical concentrate in the chemical concentrate container
61. It should be appreciated that the term "chemical" when used to describe the concentrate
in the chemical concentrate container 61 can refer to one compound or a mixture of
two or more compounds.
[0024] The chemical concentrate container 61 has an externally threaded outlet neck 62.
A closure cap 64 is threaded onto the neck 62 of the chemical concentrate container
61. The closure cap 64 has an upper wall 65, and a skirt 66 that extends downward
from the upper wall 65. The closure cap 64 has a well 68 that extends downward from
the upper wall 65. A closure cap inlet port 69 defines a concentrate inlet 70 that
is in fluid communication with the well 68.
[0025] A dip tube holder 72 is press fit over the end of the closure cap inlet port 69.
A one way valve, which is duckbill valve 73 in this example, is positioned between
the well 68 and the dip tube holder 72. A chemical dip tube 75 is press fit into the
dip tube holder 72. The duckbill valve 73 allows fluid flow from the chemical dip
tube 75 toward the well 68, and prevents flow from the well 68 back toward the chemical
dip tube 75. Alternative one way valves are also suitable for use in the dip tube
holder 72 such as a ball valve. It is contemplated that the one way valve is located
in or adjacent an opening of the chemical concentrate container 61 to prevent flow
upstream toward the restriction orifice 76.
[0026] The bottom end, or intake end, of the chemical dip tube 75 has a restriction orifice
76 that is press fit into the chemical dip tube 75. The restriction orifice 76 has
a smaller inner diameter than the inner diameter of an adjacent section of the chemical
dip tube 75. The restriction orifice 76 can be of various throughhole inner diameters
to provide a metering function. It can be appreciated that any number of different
chemical dip tubes 75 with a restriction orifice 76 can be provided with the chemical
concentrate container 61 for achieving different chemical to diluent mix ratios. For
example, a first chemical concentrate container containing a first chemical can have
a dip tube in fluid communication with a restriction orifice having a first throughhole
inner diameter in the chemical concentrate container to achieve a chemical to diluent
mix ratio of 1:5. A second chemical concentrate container containing a second chemical
can have a dip tube in fluid communication with a restriction orifice having a throughhole
inner diameter of a second smaller size to achieve a chemical to diluent mix ratio
of 1:15. A third chemical concentrate container containing a third chemical can have
a dip tube in fluid communication with a restriction orifice having a throughhole
inner diameter of a third smaller size to achieve a chemical to diluent mix ratio
of 1:32. A fourth chemical concentrate container containing a fourth chemical can
have a dip tube in fluid communication with a restriction orifice having a throughhole
inner diameter of a fourth smaller size to achieve a chemical to diluent mix ratio
of 1:64. Of course, other chemical to diluent mix ratios in the range of 1:1 to 1:1200,
1:1 to 1:100, or 1:16 to 1:256 can be achieved. Further, it is contemplated that variability
of the chemical to diluent mix ratio is plus or minus about 10 percent when operating
the pump assembly.
[0027] A closure cap outlet port 79 is press fit into the well 68 of the closure cap 64.
The closure cap outlet port 79 has an outer wall 80 that defines a concentrate outlet
81. There is a groove 82 in the outer wall 80 of the closure cap outlet port 79, and
an external O-ring 83 is located on the closure cap outlet port 79.
[0028] The fluid application system 10 includes a concentrate container attachment mechanism
85 on the spray housing 12 for attaching the chemical concentrate container 61 to
the valve body 55. The concentrate container attachment mechanism 85 includes a slide
plate 87 having an aperture 88. The concentrate container attachment mechanism 85
includes a catch pin 89 that is movable in a recess 90 of the valve body 55 by way
of a compression spring 91. The concentrate container attachment mechanism 85 includes
a push release button 92 that is mounted above a mounting bracket 94. A compression
spring 95 is positioned between a lateral protrusion 96 on the valve body 55 and an
upwardly extending tab 97 of the slide plate 87.
[0029] Looking at Figures 2 and 3, a sprayer assembly 110 is located within the sprayer
housing 12 of the fluid application system 10. The sprayer assembly 110 includes an
electric motor 130, a transmission 132 and a pump 134. The motor 130 includes a drive
gear, and the transmission 132 includes a series of three gears 138a, 138b, 138c,
a cam 140, and a cam follower shaft 142. The pump 134 includes a piston 144 that is
linearly displaceable within a pump cylinder 146 of the pump 134. The piston 144 has
an external O-ring 148 which helps clear the pump chamber formed by the pump cylinder
146. The O-ring 148 maximizes the pump suction to draw in and push out the mixture
of diluent and chemical being dispensed. Although one O-ring is depicted, it should
understood that other examples can use a different number of O-rings. The pump cylinder
146 is in fluid communication with a discharge conduit 152 which is in fluid communication
with a nozzle 154 for spraying the mixture of the chemical and the diluent.
[0030] The sprayer assembly 110 includes a trigger 156 that contacts a microswitch 158 that
controls the flow of electricity from batteries 162 to the motor 130. When the trigger
156 is depressed to contact the microswitch 158, the motor 130, by way of the transmission
132, drives the piston 144 back and forth within the pump cylinder 146 of the pump
134 to draw a mixture of the diluent and the chemical into the pump cylinder 146 and
then expel the mixture of the diluent and chemical from the nozzle 154 for spraying
the mixture of the chemical and the diluent. The pump cylinder 146 is in fluid communication
with a pump supply conduit 157 that is placed in fluid communication with the mixed
fluid supply conduit 45 by way of a sprayer connector 166 which is further described
in
U.S. Patent Application Publication No. 2008/0105713. In one example, it is contemplated that each stroke of the piston 144 expels about
0.8 to about 1.6 milliliters of the mixture of the diluent and chemical from the nozzle.
In another example, each stroke of the piston 144 expels about 1.3 milliliters of
the mixture of the diluent and chemical from the nozzle.
[0031] While Figures 2 and 3 illustrate the employment of a dual reciprocating piston-type
pump 134, a gear pump, a peristaltic pump or other suitable pumping assembly may be
substituted for the piston pump 134 without departing from the spirit of the invention.
A dual reciprocating pump such as the one illustrated in Figures 2 and 3 is advantageous
for use in the present invention to achieve a more continuous flow and/or even dispersion
or emission of the pumped material. Various alternative pump configurations are described
in
U.S. Patent No. 7,246,755.
[0032] Having described the components of the fluid application system 10, use of the fluid
application system 10 can be further described. A user fills the diluent reservoir
16 through the fill opening 31 with a diluent, preferably water. The refill cap 33
is secured over the fill opening 31 after filling.
[0033] The chemical concentrate container 61 is assembled to the sprayer housing 12 by moving
the chemical concentrate container 61 in direction A as shown in Figure 7. The closure
cap outlet port 79 of the chemical concentrate container 61 is advanced through the
aperture 88 in the slide plate 87 of the concentrate container attachment mechanism
85. The protruding ridge 37 of the diluent reservoir 16 can be positioned in the groove
63 of the chemical concentrate container 61 to assist in alignment. The upper wall
65 of the closure cap 64 contacts and then moves upward the catch pin 89 that is movable
in the recess 90 of the valve body 55 by way of the compression spring 91. The slide
plate 87 is then removed from engagement with the catch pin 89 such that the slide
plate 87 moves in relation to the mounting bracket 94 in direction B shown in Figure
7 due to the biasing force of the compression spring 95 that is positioned between
the lateral protrusion 96 on the valve body 55 and the upwardly extending tab 97 of
the slide plate 87. An inner edge of the aperture 88 in the slide plate 87 then enters
the groove 82 in the outer wall 80 of the closure cap outlet port 79 thereby attaching
the chemical concentrate container 61 to the sprayer housing 12. When the chemical
concentrate container 61 is attached to the sprayer housing 12, the closure cap outlet
port 79 moves valve stem 57 of the valve body 55 upward such that the slit 59 is uncovered
thereby allowing for fluid flow from the central passageway 58 of the valve stem 57
to the chemical inlet 53 of the manifold 40.
[0034] The chemical concentrate container 61 can be removed from the sprayer housing 12
by pressing the push release button 92 in the direction opposite to direction B in
Figure 7 so that the slide plate 87 moves in the direction opposite to direction B
and the inner edge of the aperture 88 in the slide plate 87 exits the groove 82 in
the outer wall 80 of the closure cap outlet port 79. The chemical concentrate container
61 can then be pulled in the direction opposite to direction A in Figure 7 to remove
the chemical concentrate container 61 from the sprayer housing 12.
[0035] Having filled the diluent reservoir 16 with diluent and having assembled the chemical
concentrate container 61 to the sprayer housing 12, the user can apply a mixture of
the diluent and chemical to a surface. When the trigger 156 is depressed, the motor
130 causes piston 144 to reciprocate in the pump chamber formed by the pump cylinder
146, and the pump suction draws a mixture of the diluent and chemical into the pump
cylinder 146. Specifically, the pump suction draws diluent up the diluent dip tube
29, through the duckbill valve 28 and the diluent inlet 48 of the manifold 40 and
into the mixing chamber 43 of the manifold 40. The pump suction also draws chemical
up the chemical dip tube 75, through the duckbill valve 73 and the chemical inlet
53 of the manifold 40 and into the mixing chamber 43 of the manifold 40. The amount
of chemical entering the mixing chamber 43 is controlled by the inner diameter of
the restriction orifice 76 of the chemical dip tube 75 as explained above. The amount
of chemical entering the mixing chamber 43 determines the mixing ratio of diluent
and chemical.
[0036] The pump suction draws the mixture of the chemical and the diluent created in the
mixing chamber 43 through the outlet port 44 of the manifold, through the mixed fluid
supply conduit 45, through the sprayer connector 166, through the pump supply conduit
156 and into the pump chamber. The pump 134 expels the mixture of the chemical and
the diluent into the discharge conduit 152 which is in fluid communication with the
nozzle 154 for spraying the mixture of the chemical and the diluent.
[0037] Turning now at Figure 8, another example of a fluid application system not in accordance
with the invention includes a sprayer assembly 210. The manifold 40, the diluent reservoir
16, and the chemical concentrate container 61 of the fluid application system of Figure
1 as shown in Figure 4 are in fluid communication with the sprayer assembly 210 by
way of a mixed fluid supply conduit 245. The fluid connections between the manifold
40, the diluent reservoir 16, and the chemical concentrate container 61 are all described
above and will not be repeated for the fluid application system including the sprayer
assembly 210.
[0038] The sprayer assembly 210 includes a finger operated trigger 228 for reciprocatingly
moving a piston 216 within a pump cylinder 218, alternatingly increasing and decreasing
the cylinder head space 220 to (i) draw a mixture of the diluent and chemical into
a pump chamber 222 from a mixed fluid supply conduit 245 and (ii) then expel the mixture
of the diluent and chemical from the chamber 222. A compression spring 225 biases
the piston 216 outward toward the trigger 228. A cylindrical discharge conduit 232
provides fluid communication between the chamber 222 and a nozzle 230. The discharge
conduit 232 has a discharge check valve 234 that permits fluid to move toward the
nozzle 230 and not back toward the chamber 222. A ball valve 242 permits fluid to
move toward the chamber 222 and not back toward the mixed fluid supply conduit 45.
[0039] Referring now to Figures 2 and 8, having filled the diluent reservoir 16 with diluent
and having assembled the chemical concentrate container 61 to the sprayer housing
12, the user can apply a mixture of the diluent and chemical to a surface. When the
trigger 228 is repeatedly depressed and released, the piston 216 reciprocates in the
pump cylinder 218, and the pump suction draws a mixture of the diluent and chemical
into the pump cylinder 218. Specifically, the pump suction draws diluent up the diluent
dip tube 29, through the duckbill valve 28 and the diluent inlet 48 of the manifold
40 and into the mixing chamber 43 of the manifold 40. The pump suction also draws
chemical up the chemical dip tube 75, through the duckbill valve 73 and the chemical
inlet 53 of the manifold 40 and into the mixing chamber 43 of the manifold 40. The
amount of chemical entering the mixing chamber 43 is controlled by the inner diameter
of the restriction orifice 76 of the chemical dip tube 75 as explained above. The
amount of chemical entering the mixing chamber 43 determines the mixing ratio of diluent
and chemical.
[0040] The pump suction draws the mixture of the chemical and the diluent created in the
mixing chamber 43 through the outlet port 44 of the manifold, through the mixed fluid
supply conduit 245, and into the pump cylinder 218. The pump cylinder 218 expels the
mixture of the chemical and the diluent into the discharge conduit 232 which is in
fluid communication with the nozzle 230 for spraying the mixture of the chemical and
the diluent.
[0041] An embodiment of a fluid application system 310 according to the invention is shown
in FIGS. 9-24. The fluid application system 310 is similar to the fluid application
system 10, except for the differences noted herein. Further, it is contemplated that
various embodiments described in the following paragraphs can be combined or interchanged
with various embodiments related to the fluid application system 10.
[0042] The fluid application system 310 includes a sprayer housing 312 having a first shell
313 and a second shell 314 that can be fastened together with screws or another suitable
fastening device. The sprayer housing 312 surrounds a sprayer assembly 410 that will
be described in further detail below.
[0043] Referring to Figures 9, 10, 12, and 15, the fluid application system 310 includes
a diluent reservoir 316 which in one non-limiting version holds about twelve fluid
ounces. Water is the preferred diluent, but any other fluid suitable for diluting
a concentrated liquid chemical can be used as the diluent. The diluent reservoir 316
can be formed from a suitable material such as polymeric material (e.g., polyethylene
or polypropylene). The diluent reservoir 316 has an outlet neck 317 that terminates
in a peripheral flange 318. A diluent reservoir cap 320 having an outer circular wall
321 with an inwardly-projecting inner lower rib 322 is installed on the neck 317 of
the diluent reservoir 316. In particular, the rib 322 engages an underside of the
flange 318 of the cap 320.
[0044] Referring to Figure 12, the outer circular wall 321 of the cap 320 extends further
upward to provide a central well 324 that is in fluid communication with an inlet
port 325 and a fill opening 331. As such, the diluent reservoir cap 320 operates as
a water reservoir splitter by guiding an incoming stream of refill diluent through
the fill opening 331 and by securing thereto the inlet port 325 that guides an outgoing
stream of diluent. In particular, the inlet port 325 is an open-ended cylindrical
channel with a proximal end having an integrally formed dip tube holder 326 and a
distal end adapted to receive an umbrella valve 328 assembly. The proximal end of
the inlet port 325 extends into the central well 324 and receives a diluent dip tube
329 that is press-fit into a sealing fit therein. The distal end of the inlet port
325 projects beyond the cap 320 and is characterized by a cylindrical portion that
is greater in diameter than the proximal end, thereby allowing the distal end to abut
against an outer surface of the cap 320.
[0045] As shown in Figure 13, a one-way valve, such as the umbrella valve 328a, is positioned
within the distal end of the inlet port 325 and is therefore located outside of the
cap 320. The umbrella valve 328a allows fluid to flow from the diluent dip tube 329
toward the sprayer assembly 410 and prevents fluid that is downstream of the umbrella
valve 328a from flowing back toward the diluent dip tube 329. In one non-limiting
form, the umbrella valve 328a has a cracking pressure in the range of greater than
0 kPa to 6.89 kPa (0 to 1 psi). As shown in the present embodiment, the umbrella valve
328a comprises a skirt 330a with an underside having a protruding post 339a. Alternative
one way valves are also suitable for use in the inlet port 325, such as a ball valve.
It is contemplated that the one way valve is located in or adjacent an opening of
the diluent reservoir 316 to prevent flow that is upstream of the reservoir 316 to
flow back toward an intake end of the diluent dip tube 329 that is in fluid communication
with the diluent reservoir 316 and is located therein.
[0046] Referring back to Figure 12, the fill opening 331 allows the diluent reservoir 316
to be refilled with diluent. A refill cap 333 covers the fill opening 331 and can
be removed or lifted off of the sprayer housing 312 to uncover the fill opening 331.
After refilling the diluent, the refill cap 333 is subsequently inset back onto the
sprayer housing 312 to cover the fill opening 331. In some embodiments, an exterior
surface of the refill cap 333 provides a visual indicator 332, such as an embedded
icon of a water faucet or other diluent sources, to signify the refill cap 333 to
the user. Further, a vent opening 334 is located on the refill cap 333 and traverses
through the thickness of the cap 333 toward the central well 324 of the reservoir
cap 320. The vent opening 334 opens to an umbrella valve 335 that is situated on an
umbrella seat 338, which is retained on an underside of the refill cap 333. The umbrella
valve 335 controls venting from the interior of the diluent reservoir 316 to ambient
atmosphere to restore air into the diluent reservoir 316. In a different aspect, the
diluent reservoir 316 defines an outer wall 336 with a concave sidewall 337 to rest
against the somewhat frustoconical-shaped chemical concentrate container 361. It is
contemplated that other sidewall configurations can be applied with complementary
or non-complementary shapes between the diluent reservoir 316 and the chemical concentrate
container 361. Preferably, the diluent reservoir 316 has a larger volume than the
chemical concentrate container 361. Preferably, the diluent reservoir 316 is located
forward of the chemical concentrate container 361 with respect to the direction of
spray.
[0047] As shown in Figures 10, 12, and 13, the fluid manifold 340 is located within the
sprayer housing 312 of the fluid application system 310. The manifold 340 has a main
body 342 that defines a mixing chamber 343. The manifold 340 has an outlet port 344
that is in fluid communication with the mixing chamber 343 and a mixed fluid supply
conduit 445. A fluid stream comprising a mixture of the diluent and chemical is provided
from the manifold 340 to the mixed fluid supply conduit 445 to the sprayer assembly
410 as described below.
[0048] The manifold 340 has a diluent inlet port 346 having a cylindrical outer wall 347
that defines a diluent inlet 348 of the manifold 340. An umbrella seat 349a is provided
on the outside of the outer wall 347 of the diluent inlet port 346 and contains the
umbrella valve 328a therein. As shown in Figure 13, the diluent inlet port 346 is
operatively engaged to the central well 324 of the diluent reservoir cap 320 by inserting
one end of the inlet port 346 into the umbrella seat 349a. The umbrella seat 349a
is further inserted into the distal end of the inlet port 325, which extends to the
proximal end that is located in the central well 324. As such, the umbrella seat 349a
connects the manifold 340 to the diluent inlet port 325 and allows communication of
fluid therethrough. Further, the umbrella seat 349a provides a sealing surface through
which the umbrella valve 328a is retained. The sealing surface comprises a raised
ridge 350a protruding toward an underside of a skirt 330a of the umbrella valve 328a.
In some embodiments, the sealing surface is an O-ring.
[0049] The manifold 340 has a chemical inlet port 351 in fluid communication with the mixing
chamber 343. The chemical inlet port 351 has an outer wall 352 that defines a chemical
inlet 353 of the manifold 340. The chemical inlet port 351 is further in fluid communication
with a valve stem 357 of the chemical concentrate container 361. In particular, the
outer wall 352 of the chemical inlet port 351 is inserted into an umbrella seat 349b,
which is further inserted into an actuator body 355 having an entry port dimensioned
to engage an upper portion of the valve stem 357 thereby and mechanically actuating
the valve stem 357. The valve stem 357 is received in a valve body 354 and biased
toward the actuator body 355 with a spring 356, such that the actuator body 355 can
move the valve stem 357 to an open position when the chemical concentrate container
361 is attached to the sprayer housing 312. It is contemplated that other biasing
elements for biasing the valve stem 357 into a closed position can be utilized. The
actuator body 355 further includes a central passageway 358 that is aligned with a
channel 359 downstream thereof. An inner space of the central passageway 358 is partially
blocked by a portion of a post 339b that is fixed to an underside of a skirt 330b
of an umbrella valve 328b, which is movably retained in the channel 359 of the umbrella
seat 349b. In one non-limiting form, the umbrella valve 328b has a cracking pressure
in the range of greater than 0 kPa to 6.89 kPa (0 to 1 psi). Similar to the umbrella
seat 349a, the umbrella seat 349b includes a sealing surface that comprises a raised
ridge 350b protruding toward an underside of the skirt 330b of the umbrella valve
328b. As such, the chemical concentrate released from the chemical concentrate container
361 travels through the flow passageway 358a of the valve stem 357, into the channel
359, past the umbrella valve 328b and toward the chemical inlet port 351.
[0050] The manifold 340 further includes a flow adjustor 360 located in the manifold 340
and structured to vary an amount of flow through the chemical inlet 353 such as by
blocking off a portion of the chemical inlet 353. In particular, the flow adjustor
360 can be threaded to corresponding threads in the manifold 340 or friction-fit therein,
such that the user can alter the position of the flow adjustor 360 and vary the amount
of chemical through the chemical inlet 353, or vary other flow characteristics in
the manifold 340. In one aspect, the flow adjustor 360 is a rubberized plug that closes
off an end of the manifold 340. In another aspect, the flow adjustor 360 can be manipulated
to alter flow or mixing characteristics within the manifold 340. An end of the flow
adjustor 360 may extend through the sprayer housing 312 allowing the user to alter
the position of the flow adjustor 360 in the manifold 340. The flow adjustor 360 allows
the user to vary the chemical to diluent mix ratio.
[0051] In one non-limiting version of the fluid application system 310, the chemical concentrate
container 361 holds about ten fluid ounces. The concentrate can be selected such that
when the concentrate is diluted with the diluent, any number of different fluid products
is formed. Non-limiting example products include general all purpose cleaners, kitchen
cleaners, bathroom cleaners, dust inhibitors, dust removal aids, floor and furniture
cleaners and polishes, glass cleaners, degreasers, carpet cleaners, peroxide-containing
cleaners, anti-bacterial cleaners, fragrances, deodorizers, soft surface treatments,
fabric protectors, laundry products, fabric cleaners, fabric stain removers, tire
cleaners, dashboard cleaners, automotive interior cleaners, and/or other automotive
industry cleaners or polishes, or even insecticides. The chemical concentrate container
361 can be formed from a suitable material such as polymeric material (e.g., polyethylene
or polypropylene), and in certain embodiments, the chemical concentrate container
361 comprises a transparent material that allows the user to check the level of chemical
concentrate in the chemical concentrate container 361. It should be appreciated that
the term "chemical" when used to describe the concentrate in the chemical concentrate
container 361 can refer to one compound or a mixture of two or more compounds.
[0052] Turning now to Figures 12, 13, and 24, the chemical concentrate container 361 has
an outlet neck 362. A closure cap, hereon referred to as a mounting cup 364, is secured
onto the outlet neck 362 of the chemical concentrate container 361. In particular,
the mounting cup 364 has an upper plate 365 that is generally circular and covering
at least a portion of the outlet neck 362, which defines a hollow outlet 363 of a
closure of the chemical concentrate container 361. The upper plate 365 extends to
an inner skirt 366 at a central, underside portion of the upper plate 365 toward the
chemical concentrate container 361 to retain the valve body 354 therein. The upper
plate 365 further defines outer skirts about a periphery of the upper plate 356 that
extend as walls away from the side of the mounting cup 364. In particular, an outer,
lower skirt 367a is defined by walls extending downwardly about the periphery of the
upper plate 365 to provide corresponding threads, or other engaging mechanisms, to
the outlet neck 362 of the chemical concentrate container 361. An outer, upper well
367b extends upwardly from the periphery of the upper plate 365 and houses the valve
stem 357 which protrudes therein. The upper well 367b further includes a peripheral
flange 368 extending from an outer surface thereof to assist in attaching the chemical
concentrate container 361 to the fluid application system 310, as further described
below. In the present embodiment, the peripheral flange 368 extends radially outward
from an end of the wall or the outer, upper well 367b of the mounting cup 364. The
mounting cup 364 functions as a mounting element and can comprise a metallic or a
polymeric material, such as polyethylene or polypropylene.
[0053] As shown in Figure 24, in a particular aspect, the valve body 354 that is fitted
within the inner well 366 of the mounting cup 364 defines a valve body inlet port
369 having a hollow channel 378, which is further described below. One end of the
valve body inlet port 369 protrudes into the chemical concentrate container 361 and
defines an end of the hollow channel 378 as a concentrate inlet 370. In the present
embodiment, the concentrate inlet 370 is characterized by an angled outer surface
371 at the edge of the valve body inlet port 369 where the surface 371 tapers inwardly
toward the centrally-disposed channel 378. It is contemplated that the tapered design
facilitates assembly of a chemical dip tube 375, as described further below, which
can be slipped over the tapered portion and press-fit into a sealing fit onto the
valve body inlet port 369 over an entry orifice thereof. Further, the mounting cup
364 defines a closed space, such as a valve cavity 372, that secures a first end of
380 the spring-biased valve stem 357 therein. A second end 381 of the valve stem 357
extends out of the mounting cup 364 on a side opposed to the valve cavity 372 and
defines an exit opening 382 of the valve stem 357. When in the open position, the
second end 381 of the valve stem 357 is located at a position on the longitudinal
axis AX (see Fig. 24) of the mounting cup 364 plus or minus four millimeters (0.157
inches) from the transverse reference plane F (see Fig. 24) at the bottom of the peripheral
flange 368 of the mounting cup 364. A portion of the upper plate 365 of the mounting
cup 364 defines a circular stem gasket 373 that the valve stem 357 projects through.
The stem gasket 373 is approximately centrally disposed on the mounting cup 364 and
is adapted to fit substantially snugly around the valve stem 357 to cover one or more
valve stem orifices 374 disposed circumferentially thereof. In particular, the valve
stem orifices 374 are circumferential openings through a wall of the valve stem 357
that allow chemical inside the valve body 354 to enter the valve stem 357. Initially,
chemical enters the valve body 354 by way of the chemical dip tube 375, which is press-fit
around the valve body inlet port 369 to communicate a volume of chemical concentrate
from the chemical concentrate container 361 into the valve body 354. In a closed position,
fluid flow is blocked between the valve stem 357 and the valve cavity 372 by way of
the stem gasket 373. In an open position, fluid flow is permitted from the valve cavity
372 through the stem orifices 374, into the valve stem 357 and through the exit opening
382 of the valve stem 357.
[0054] As shown in Figure 24, in some embodiments, the valve body inlet port 369 comprises
a restriction orifice 376 for restricting a volume of chemical concentrate from reaching
the valve stem 357. In particular, the restriction orifice 376 is defined by an angled
generally conical wall 377 that converges inwardly from an inner surface of the valve
body inlet port 369 and more particularly extends inwardly from the hollow channel
378 at a distal end, otherwise known as an entry orifice, of the channel 378 from
the concentrate inlet 370. In other embodiments, the restriction orifice 376 is characterized
by a combination of all or a portion of the hollow channel 378 and the angled wall
377. Still, in other embodiments, the hollow channel 378 also comprises angled or
tapering surfaces in addition to the angled wall 377 of the restriction orifice 376,
or has a uniform diameter, to assist in restriction of fluid access to the valve stem
357. The wall 377 may also be annular with right angle corners. It is noted that upon
activation of the fluid application system 310, the valve stem 357 is depressed downward
by the actuator body 355 to expose the valve stem orifices 374 and draw a flow of
chemical concentrate into the chemical inlet 353 of the fluid manifold 340.
[0055] It is contemplated that the restriction orifice 376 has a smaller inner diameter
than the inner diameter of an adjacent section of the chemical dip tube 375 and/or
the concentrate inlet 370, and/or the hollow channel 378. The restriction orifice
376 can be of various throughhole inner diameters, such as 0.003 to 0.028 inches (0.07-0.7
millimeters), to provide a metering function and/or for achieving different chemical
mix ratios. Among other things, the restriction orifice 376, the umbrella valve 328a,
and the umbrella valve 328b control variability when achieving different chemical
mix ratios. Test results of restriction orifices in the range of 0.005-0.020 inches
(0.127 - 0.508 millimetres ) showed chemical to diluent mix ratios of 1:15 to 1:59.
For example, a first chemical concentrate container containing a first chemical can
have a dip tube in fluid communication with a restriction orifice having a first throughhole
inner diameter in the chemical concentrate container to achieve a chemical to diluent
mix ratio of 1:5. A second chemical concentrate container containing a second chemical
can have a dip tube in fluid communication with a restriction orifice having a throughhole
inner diameter of a second smaller size to achieve a chemical to diluent mix ratio
of 1:15. A third chemical concentrate container containing a third chemical can have
a dip tube in fluid communication with a restriction orifice having a throughhole
inner diameter of a third smaller size to achieve a chemical to diluent mix ratio
of 1:32. A fourth chemical concentrate container containing a fourth chemical can
have a dip tube in fluid communication with a restriction orifice having a throughhole
inner diameter of a fourth smaller size to achieve a chemical to diluent mix ratio
of 1:64. Of course, other mix ratios in the range of 1:1 to 1:1200, 1:1 to 1:100,
or 1:16 to 1:256 can be achieved. Further, it is contemplated that variability of
the mix ratio is plus or minus about 10 percent when operating the pump assembly.
The chemical to diluent mix ratio can be further controlled by using a capillary dip
tube in combination with the restriction orifice 376. Alternatively, the restriction
orifice 376 can be omitted and the capillary dip tube can control the chemical to
diluent mix ratio. A capillary dip tube wicks product from surface tension. A first
chemical concentrate container containing a first chemical can have a capillary dip
tube having a first inner diameter, and a second chemical concentrate container containing
a second chemical can have a capillary dip tube of a second inner diameter.
[0056] The fluid application system 310 includes a concentrate container attachment mechanism
385 on the sprayer housing 312 for attaching the chemical concentrate container 361
to the actuator body 355. The concentrate container attachment mechanism 385 includes
a moveable collar 387 having an aperture 388 that is adapted to engage the peripheral
flange 368 of the mounting cup 364. In particular, a compression spring is positioned
adjacent to an inner side of a push release button 392 to bias the push release button
392 outward of the sprayer housing 312. To release the chemical concentrate container
361, the user presses the push-release button to slide the moveable collar 387 laterally
within the sprayer housing 312 and disengage the peripheral flange 368 of the mounting
cup 364. Upon disengaging the peripheral flange 368, the chemical concentrate container
361 can be freely removed from the sprayer housing 312.
[0057] Turning now to Figure 14, the chemical concentrate container 361 is assembled to
the sprayer housing 312 by moving the chemical concentrate container 361 in direction
A. In particular, by moving the chemical concentrate container 361 toward the sprayer
housing 312, the mounting cup 364 of the chemical concentrate container 361 is advanced
through the aperture 388 in the moveable collar 387 of the concentrate container attachment
mechanism 385. The spring-biased moveable collar 387 catches an underside of the peripheral
flange 368 of the mounting cup 364 creating an audible click. In the present embodiment,
a convex sidewall 393 of the chemical concentrate container 361 juxtaposes or slides
adjacently to the concave sidewall 337 of the diluent container 316.
[0058] Still referring to Figure 14, the chemical concentrate container 361 can be removed
from the sprayer housing 312 by pressing the push release button 392 so that the container
361 can be removed in substantially the opposite of direction A. In particular, the
pushing the push release button 392 causes the moveable collar 387 to reposition laterally
and disengage its aperture 388 from the peripheral flange 368 of the mounting cup
364. The chemical concentrate container 361 can then be pulled in the direction opposite
to direction A to remove the chemical concentrate container 361 from the sprayer housing
312.
[0059] Turning now to Figures 10 and 11, the sprayer assembly 410 is located within the
sprayer housing 312 of the fluid application system 310. The fluid manifold 340, the
diluent reservoir 316, and the chemical concentrate container 361 of the fluid application
system 310 are in fluid communication with the sprayer assembly 410 by way of a mixed
fluid supply conduit 445. The fluid connections between the manifold 340, the diluent
reservoir 316, and the chemical concentrate container 361 are all described above
and will not be repeated for the fluid application system including the sprayer assembly
410.
[0060] The sprayer assembly 410 includes a finger operated trigger 428 for reciprocatingly
moving a piston 416 within a pump cylinder 418, alternatingly increasing and decreasing
the pump cylinder head space 420 to (i) draw a mixture of the diluent and chemical
into a pump chamber 422 from the mixed fluid supply conduit 445 and (ii) then expel
the mixture of the diluent and chemical from the chamber 422. A compression spring
425 biases the piston 416 outward toward the trigger 428. A cylindrical discharge
conduit 432 provides fluid communication between the pump chamber 422 and a nozzle
430. In the present embodiment, the discharge conduit 432 has a discharge check valve
434 that permits fluid to move toward the nozzle 430 and not back into the discharge
conduit 432 or the pump chamber 422.
[0061] Still referring to Figures 10 and 11, having filled the diluent reservoir 316 with
diluent and having assembled the chemical concentrate container 361 to the sprayer
housing 312, the user can apply a mixture of the diluent and chemical to a surface.
When the trigger 428 is repeatedly depressed and released, the piston 416 reciprocates
in the pump cylinder 418, and the pump suction draws a mixture of the diluent and
chemical into the pump cylinder 418. Specifically, the pump suction draws diluent
up the diluent dip tube 329, through the inlet port 325 which operatively connects
the dip tube 329 to the umbrella valve 328a, through the umbrella seat 349a, which
operatively connects the inlet port 325 to the diluent inlet port 346 of the fluid
manifold 340. Simultaneously, the pump suction also draws chemical up the chemical
dip tube 375, through the restriction orifice 376 of the valve body 354 that secures
the valve stem 357 and further past the umbrella valve 328a in the actuator body 355
to the chemical inlet 353 of the fluid manifold 340. Among other things, the amount
of chemical entering the mixing chamber 343 is controlled by the inner diameter of
the restriction orifice 376, as explained above, and determines the mixing ratio of
diluent and chemical. It is contemplated that when diluent is depleted from the diluent
reservoir 316, chemical concentrate is not dispensed from the chemical concentrate
container 361.
[0062] The pump suction continues to draw the mixture of the chemical and the diluent created
in the mixing chamber 343 through the outlet port 344 of the fluid manifold 340, through
the mixed fluid supply conduit 445, and into the pump cylinder 418. The pump cylinder
418 expels the mixture of the chemical and the diluent into the discharge conduit
432 which is in fluid communication with the nozzle 430 for spraying the mixture of
the chemical and the diluent. The fluid application system 310 is configured such
that differences in the extent of pull on the finger operated trigger 428 do not vary
the chemical to diluent mix ratio. For example, a half pull (i.e., a short stroke)
and a full pull on the finger operated trigger 428 yield the same chemical to diluent
mix ratio. Optionally, the refill cap 333, the push release button 392, the trigger
428, and the nozzle 430 may have a common color to identify user action points on
the fluid application system 310.
[0063] Turning now to Figure 15, a detailed view of one embodiment of the diluent reservoir
316 of Figure 1 is shown. The diluent reservoir 316 is adapted to be secured to the
sprayer housing 312 through a securing orifice 450 that is provided on a protruding
flap 452. It is contemplated that a nail, rod, nut and bolt assembly, or other corresponding
engagement mechanism is inserted through the securing orifice 450 to attach the diluent
reservoir 316 to the sprayer housing 312. In one embodiment, the diluent reservoir
316 is not removable by a user. Further, it is contemplated that the peripheral flange
318 circumferentially surrounding all or a portion of the outlet neck 317 engage the
diluent reservoir cap 320 that is located within the sprayer housing 312. As such,
either or both of the peripheral flange 318 and the securing orifice 450 assists in
removably or more permanently attaching the diluent reservoir 316 to the sprayer housing
312. Further, the outer wall 336 of the diluent reservoir 316 is generally rectangular
and box-shaped with one side of the outer wall 336 defining the concave sidewall 337.
As noted previously, the concave sidewall 337 is adapted to be geometrically-compatible
with the convex sidewall 393 of the adjacent or juxtaposed chemical concentrate container
361. It can be appreciated that any geometric configurations can be applied to either
or both of the concave sidewall 337, the convex sidewall 393, or other portion of
the diluent reservoir 316 or the chemical concentrate container 361. Further, it is
contemplated that the outer wall 336 is substantially or slightly transparent to allow
the user to monitor a fill level of the diluent reservoir 316. In other embodiments,
the diluent reservoir 316 is substantially less transparent, opaque, and/or comprises
a measuring scale of ounces, milliliters, a refill-indicating line, or other marks
that may be useful for operation.
[0064] Turning now to Figures 16 and 17, one embodiment of a chemical reservoir container
561 is shown comprising a one-way valve on a mounting cup 564. The chemical reservoir
container 561 and the mounting cup 564 may be similar to the chemical reservoir container
361 and the mounting cup 364 described previously, except for the differences noted
herein. In particular, the mounting cup 564 provides an upper plate 565 and a peripheral
flange 568, which is received in the attachment mechanism 385 described above. The
upper plate 565 receives therethrough a valve stem 557 having a flow passageway 558
that is fluidly aligned with a chemical dip tube 575, which extends from an underside
of the upper plate 565 into the chemical reservoir container 561. Further, the upper
plate 565 provides the one-way valve, such as a duckbill valve 580, that is radially
spaced from the valve stem 557 and the valve body 554. In one non-limiting form, the
duckbill valve 580 has a cracking pressure in the range of 0 kPa to -6.89 kPa (0 to
-1 psi) (with the negative indicating flow direction). In one non-limiting form, the
duckbill valve 580 is normally open. The duckbill valve 580 creates a liquid closed
system which is liquid tight but not air tight.
[0065] As shown in Figures 17 and 24, the duckbill valve 580 is retained on the underside
of the upper plate 565 by a valve retainer 582, which houses a portion of the duckbill
valve 580 through a channel 584 that terminates with an inwardly projecting ring 586.
The inwardly projecting ring 586 is a circumferential ring having a smaller diameter
than the channel 584, such that the duckbill valve 580 can be slidingly placed within
the channel 584 until a surface of the valve 580 catches the inwardly projecting ring
586 to prevent further insertion. In one aspect, as shown in Figure 24, the one-way
valve assembly is provided on the mounting cup 364 described above. It is contemplated
that a portion of the valve retainer 582 is integrally formed or shares a portion
of the inner skirt 366 that houses a valve body 554, which may be similar to the valve
body 354. In an aspect, the duckbill valve 580 permits ambient air to enter the chemical
concentrate container 561 to restore an internal pressure of the reservoir 561 by
replacing space left by chemical dispensed from the reservoir 561. For instance, a
vacuum can be created within the chemical concentrate container 561 upon exit of chemical
concentrate leaving the reservoir 561. The duckbill valve 580 allows air to enter
the reservoir 561 to restore an original pressure of the chemical concentrate container
561, which may be approximately an ambient pressure outside of the reservoir 561.
Other valves that can permit entry of gases and restoration of the internal pressure
may also be utilized, as described further below.
[0066] Turning now to Figures 18-20, a two-way valve assembly is shown on a chemical reservoir
container 661. A mounting cup 664 having a valve stem 657 protruding therethrough
further provides an umbrella valve 680 adjacent to the valve stem 657. The valve stem
657 is in fluid communication with a chemical dip tube 675 that is retained within
a valve body 654 attached to the mounting cup 664 and extended into the chemical concentrate
container 661. The umbrella valve 680 is retained within a valve retaining orifice
682, which includes a channel 684 and an inwardly projecting ring 686 similar to the
valve retaining mechanism described above. Further, the mounting cup 664 provides
at least one valve seat flow hole 650 through an upper plate 656 of the cup 664. As
shown in Figure 19, two valve seat flow holes 650 are provided, with each valve seat
flow hole 650 generally semicircular shaped. It is contemplated that other valve seat
flow hole configurations can be applied, such as a circular valve seat flow hole.
[0067] As shown in Figure 20, the two-way umbrella valve 680 includes the skirt 688 which
rests above the upper plate 656 and a post 690 that extends through the valve retaining
orifice 682. The post 690 comprises a one-way valve, such as the one-way duckbill
valve 580 described above. As such, the skirt 688 is perforated with an open top 692
to expose the duckbill valve 580 retained within the post 690 extending from the skirt
688. The two-way valve permits gas generated by chemical concentrate to escape from
the chemical concentrate container 561 and further permits ambient air to enter the
reservoir 561 to displace chemical dispensed therefrom. In particular, it is the duckbill
valve 580 that permits ambient air to enter the chemical concentrate container 661
to displace chemical dispensed therefrom and the skirt 668 permits gas generated by
the chemical concentrate to exit through the valve seat flow hole 650. For example,
when the chemical concentrate container 561 contains a concentrate including hydrogen
peroxide, pressure may build in the chemical concentrate container 561 at up to 6.89
kPa (1 psi) of pressure per day. The skirt 668 permits gas generated by the peroxide-containing
concentrate to exit through the valve seat flow hole 650.
[0068] Turning to Figures 21 and 22, a third embodiment of a chemical concentrate container
761 having a gas-permeable valve disposed on a mounting cup 764 is shown. The mounting
cup 764 has a valve stem 757 protruding therethrough, which is retained by a valve
body 754 having a chemical dip tube 775 secured thereto. The gas-permeable valve may
comprise a membrane 780 of expanded polytetrafluoroethylene such as a Gore
™ vent available from W. L. Gore & Associates, Inc., Elkton, Maryland, USA. The membrane
780, which may comprise another suitable porous polymeric membrane, is located on
an upper plate 767 of the mounting cup 764. In some embodiments, the mounting cup
764 may provide a recess for receiving the membrane 780 therein. Further, the upper
plate 767 may have gas-permeable characteristics similar to that of the membrane 780.
In the present embodiment, the membrane 780 is a semicircular sheet of gas-permeable
material surrounding a portion of the valve stem 757, although other shapes can be
contemplated, such as a full ring or a plurality of sections of the material. It is
contemplated that the gas-permeable material permits ambient air to enter the chemical
concentrate container 761 to displace chemical dispensed therefrom and prevents liquids
from exiting the container 761.
[0069] Referring to Figure 23, a container of flexible material, such as a flexible inner
bag 880, can be disposed within a chemical concentrate container 861 to hold a supply
of chemical concentrate therein. It is contemplated that the flexible inner bag 880
has an opening 882 that is secured to a valve body 854 with assistance from a bag
bracket 884. The bag bracket 884 may snugly fit around the valve body 854 and/or a
portion of a valve stem 857 mounted within the valve body 854 to press-fit the inner
bag 880 around the valve body 854. Further, the bag bracket 884 may define a circumferential
lip 886 that is adapted to be received over an outlet neck 817 of the chemical concentrate
container 861. As such, the circumferential lip 886 is further retained onto the outlet
neck 817 by an inner surface of the mounting cup 864, such as an inner surface defined
by an underside of a lower well 876 of the mounting cup 864. The lower well 876 may
be similar to the lower well 367a described above. Furthermore, it is contemplated
that a venting apparatus or an inner plate similar to the inner plates described above
are not provided on the mounting cup 864, since the flexible inner bag 880 can shrink
during usage. In one aspect, the flexible inner bag 880 can be used with or without
the chemical concentrate container 861.
[0070] Further, it is contemplated that a kit can be provided to include a first chemical
concentrate container and a second chemical concentrate container. The first and second
chemical concentrate containers can comprise any of the above-described chemical concentrate
containers. It is contemplated that the first chemical concentrate container can contain
a first chemical and include a valve body that has a first entry orifice, which has
a first restriction orifice located therein. Further, it is contemplated that the
second chemical concentrate container contains a second chemical and includes a second
entry orifice in fluid communication with a closed space of the second container.
The second entry orifice has a second restriction orifice located therein. It is contemplated
that the first restriction orifice comprises different restriction characteristics,
such as a different transverse area, than the second restriction orifice. Further,
the first and the second chemicals can be the same or different. It can be appreciated
that additional chemicals and chemical concentrate containers can be incorporated
to the fluid application system described herein.
[0071] Turning to Figures 25-28, a general fluid application system 900 is described that
comprises a sprayer head 902 having a nozzle 904 and a trigger 906 provided on or
adjacent to a front side 908 of the sprayer head 902, which opposes a rear side 910
thereof. In general, the front side 908 of the sprayer 902 corresponds to a front
912 of the fluid application system 900 and the rear side 910 of the sprayer head
902 corresponds to a rear 914 of the fluid application system 900. It is also contemplated
that other sprayer head 902 geometries may be used, which may be generally characterized
as having front portions for emitting a spray and opposing rear portions. It is further
contemplated that the trigger 906 or a button may be placed anywhere on a sprayer
head, but conventionally is placed on the front side 908 of such devices.
[0072] The sprayer head 902 is disposed on a sprayer neck 916, which may be generally referred
to as a gripping portion or a member having a neck body 918. In the present exemplary
embodiment, the sprayer head 902 is provided on an upper end 920 or distal end of
the neck body 918. A lower end 922 or proximal end of the sprayer neck 916 is disposed
proximate a refill container 924. More specifically, the lower end 922 of the sprayer
neck 916 of the present embodiment is provided adjacent the refill container 924 and
adjacent the diluent container 926. In some embodiments, as illustrated in Figures
25 and 26, the sprayer neck 916 attaches to and/or is adjacent to a container housing
928 or retention structure, which receives therein at least a portion of the refill
container 924 and the diluent container 926. In other embodiments, it can be appreciated
that the container housing 928 is formed by the lower end 922 of the sprayer neck
916. In general, it is contemplated that all or a portion of the neck body 918 that
is grippable by a user is provided above all or a portion of the refill container
924 and the diluent container 926, or, in other embodiments that it is provided above
one or more reservoirs for holding a product therein. In some embodiments, the sprayer
head 902 may be characterized as disposed on a top half 930 of the fluid application
system 900 and that the refill container 924 and the diluent container 926 (or the
one or more reservoirs) are disposed on a bottom half 932 of the system 900.
[0073] Figure 26 shows a front view of the fluid application system 900, whereby the trigger
906 and the nozzle 904 on the front side 908 of the sprayer head 902 are disposed
above the diluent container 926. Figure 27 shows a rear view of the fluid application
system 900 with the rear side 910 of the sprayer head 902 disposed above the refill
container 924. In both of the front and rear views of Figures 26 and 27, the sprayer
neck 916 and the container housing 928 extend between the sprayer head 902 and all
or a portion of the refill and diluent containers 924, 926.
[0074] Turning to Figure 28, the positioning of the diluent container 926 relative to the
refill container 924 is shown when attached to the container housing 928. The refill
container 924 comprises a convex sidewall 934 that is adjacent to a concave sidewall
936 of the diluent container 926. Other geometric shapes for the refill container
924 and the diluent container 926 can be contemplated that may be complementary or
non-complementary together, such as flat sidewalls, a convex diluent sidewall adjacent
to a concave refill sidewall, flexible or amorphous sidewalls, and the like. Further,
the refill and diluent containers 924, 926 may be transparent to provide a visual
indication of the fluid level in the containers 924, 926. With the refill container
924 and the diluent container 926 assembled onto the fluid application system 900,
it is contemplated that the sprayer neck 916 operates as a handle or a gripping portion
for a user to grasp and actuate the fluid application system 900.
[0075] In a particular aspect, the dispensing system described above is adapted to simultaneously
dispense product contained within at least two separate reservoirs for exit through
the same sprayer head assembly. Such multi-reservoir dispensers have structural and
operational requirements that are different than single-container reservoirs, which
need only dispense a product contained within a single container. For instance, structural
considerations such as placement, balance, and attachment of the multiple reservoirs
to the multi-reservoir dispenser are introduced, such as allowing for each reservoir
to be attached and/or detached independently. Further, the multi-reservoir dispenser
needs to be adapted to support the additional weight and dynamics of the additional
reservoir(s). Even further, the multi-reservoir dispensers are typically sized with
about the same geometry as single-reservoir dispensers to allow handheld user operation,
yet may have more components and moving parts for dispensing the multiple products.
Thus, multi-reservoir dispensers have more imbalances, weight considerations and complexities
within their systems. As such, the multi-reservoir dispensers behave and respond differently
during operation than single-reservoir dispensers.
[0076] Furthermore, some multi-reservoir dispensers, such as the fluid application system
900 described herein, are adapted to dispense the constituent components from one
reservoir at a faster rate than the constituent components from the remaining reservoir
to achieve different mix ratios that comprise the product being dispensed. As such,
one reservoir is depleted before the remaining reservoir during normal operation.
For instance, one reservoir may be half full while the remaining reservoir is substantially
fuller than the other reservoir. The different dispensing rates between the two reservoirs
create dynamic imbalances throughout the normal operational period, which are not
as prevalent in single reservoir dispensers or multi-reservoir dispensers having the
same dispensing rate for the multiple reservoirs. In a particular aspect, the dynamic
imbalances that occur are not linear as they may be in a single reservoir dispenser,
because there are two reservoirs having different weight distributions and different
changes in weight throughout operation. While a single-reservoir dispenser is optimized
for a particular operational envelope exhibiting dynamics that are generally linear
over time, a multi-reservoir container must be optimized for a variety of dynamic,
non-linear behaviors, such as the changing balance of the system due to weight differences
between the reservoirs, which effect the center of gravity of the system and torque
forces exhibited by the system. As such, for multi-reservoir dispensers, it is necessary
to create an optimal design for a complex operational envelope while still balancing
ergonomics and ease-of-use considerations for the user.
[0077] The above concerns are addressed herein in various manners as described below and
as shown in Figures 25-35. To achieve a balanced multi-reservoir dispenser that provides
optimum performance for a dispensing period having dynamic imbalances during normal
usage, the dispenser herein is designed for an operational profile that is most prevalent
during the lifetime of the dispenser. In one embodiment, the operational profile is
a state when the diluent reservoir 926 is partially full and the refill reservoir
294 is full. In an alternative embodiment, the operational profile is a state when
the diluent reservoir 926 is about 70 percent to about 80 percent full and the refill
reservoir 294 is substantially full or fuller than the diluent reservoir 296. In another
alternative embodiment, the operational profile is a state when the diluent reservoir
926 is about 40 percent to about 60 percent full and the refill reservoir 924 is substantially
full or more full than the diluent reservoir 926. In the present embodiment, the operational
profile of the fluid application system 900 is considered with the diluent reservoir
at about 50 percent full and the refill reservoir 924 being full or substantially
full.
[0078] It is contemplated that a balanced system for any of the operational profiles above
can be achieved by optimizing the placement of the sprayer neck 916 on the fluid application
system 900. Referring to Figures 25-27, it is contemplated that the sprayer neck 916
is characterized by a grippable portion of the fluid application system 900 that is
adapted to be grasped by the user when actuation of the system 900 is desired. In
the present embodiment, the grippable portion is provided between the sprayer head
902 and the refill and diluent containers 924, 926. It can be contemplated in other
systems, however, that the grippable portion is above or includes the sprayer head
902, or the grippable portion is below or above the refill and diluent containers
924, 926, or in any other possible orientation. In general, the sprayer neck 916 is
characterized by a surface adapted to receive the user's grip during deployment and
operation of the device. It is noted that the sprayer neck 916 may extend beyond the
gripping surface as well. In one embodiment, the gripping surface comprises finger
grips, ribs, rubberized tracks, indents or other markings to indicate its purpose
and/or to facilitate its grasping.
[0079] Referring to Figures 25-27, a lower end or a lower boundary of the sprayer neck 916
or gripping portion may be better understood. In one embodiment, the sprayer neck
916 is defined as the neck body 918 disposed above or received over the refill and
diluent containers 924, 926, which have an uppermost portion of both of the containers
that extends to a line C in Figure 25. In particular, the lower end 922 of the sprayer
neck 916 is received over the refill and diluent containers 924, 926 and the neck
body 918 continuously extends thereabove. In a different embodiment, the lower end
922 extends below the line C, thereby receiving a portion of the refill and diluent
containers 942, 926, therein. In other aspects, the sprayer neck 916 can be defined
by the lower end 922 of the sprayer neck 916 having a neck securement region 1000,
which may be further emphasized by a concave surface or inflection point IP which
separates the container housing 928 from the lower end 922 of the sprayer neck 916.
The inflection point IP may occur above the line C as shown in Figure 25 or below
it, and such a demarcation of the lower boundary of the neck 916 is shown as a line
D in the present embodiment. In a further aspect, the lower end 922 of the sprayer
neck 916 is an end of the neck 916 that is proximal to retention structures within
the container housing 928 for retaining the refill and diluent containers 924, 926.
Even further, it is contemplated that the sprayer neck 916 comprises a lower end 922
defined by a narrowest cross-section portion of the container housing 928 which retains
the refill and diluent containers 924, 926. As shown in Figure 25, it is contemplated
that the narrowest cross-section of the container housing 928 also defines an uppermost
region of the housing 928 where the lower end 922 of sprayer neck 916 begins. However,
regardless of the manner in which the lower boundary of the neck is defined given
a particular dispensing system and neck, it is understood that all portions of the
neck must be grippable and/o adapted to be so gripped during normal use of the sprayer,
i.e., actuation and movement of the sprayer. In the present embodiment, the lower
boundary of the neck 916 is indicated by the line D.
[0080] Still referring to Figure 25, the sprayer neck 916 is generally displaced off-centered
or toward the rear 914 of the fluid application system 900. It is contemplated that
this positioning may contribute to an optimized system that is balanced for the most
common usage conditions, and particularly for the condition where the diluent container
926 is fifty percent full while the refill container 924 is full. In an aspect, the
sprayer neck 916 is disposed substantially above the refill container 924, which is
dispensed less quickly and therefore exhibits less change (or a lower loss) in weight
and mass over a period of dispensing. In one particular embodiment, a distance X is
measured between peripheral portions of the refill and diluent containers 924, 926
as shown in Figure 25. More particularly, the refill and diluent containers 924, 926
may be juxtaposed or adjacent to one another and include portions that are distal
to other portions of the corresponding containers. In the particular embodiment, two
parallel lines P1, P2 tangent to the outermost distal portions of the refill and diluent
containers 924, 926 represent a linear distance X, which extends therebetween, transversely
or perpendicular to the parallel lines P1, P2. Such a distance X may also be the distance
between distal portions of a single container with multiple reservoirs. In some embodiments,
it is contemplated that the lower end 922 of the sprayer neck 916 has a cross section
with a width taken from the front 912 to the rear 914 that is between about 0.30*X
to about 0.60*X; more preferably between about 0.40*X to about 0.50*X; and most preferably
between about 0.42*X to about 0.48*X. In some embodiments, it is contemplated that
the inflection point IP is positioned beyond a point X/2 of the linear distance X.
[0081] Turning to Figures 29A-C, it is further understood that the containers or reservoirs
may have different volume and/or geometric shapes, but it is also understood that
a linear distance between distal portions of such containers or reservoirs may be
calculated based on a straight line defined between the outer portions that are farthest
from one another. For instance, Figure 29A illustrates a fluid dispensing system 900b
comprising two angular containers 924b, 926b received within a neck 916b that extends
to a sprayer head 902b. In this configuration, a horizontal distance X
B is defined between two parallel lines P3, P4 that are tangent to the outermost peripheries
of the containers 924b, 926b. Further, it is noted that the neck 916b is centrally
disposed and comprises a height Y
B that receives therein a portion of the containers 926b, 924b.
[0082] Figures 29B and 29C show other geometric shapes for containers that define a horizontal
distance based on the outer peripheries of their geometries. In particular, Figure
29B shows two rounded containers 924c, 926c that define a horizontal distance X
c between two parallel lines P5, P6, which bound the outermost peripheries of the containers
924c, 926c. Similarly, Figure 29C illustrates two non-complementary shaped containers
924d, 926d that define a horizontal distance X
D between two parallel lines P7, P8, which bound the outermost peripheries thereof.
It is contemplated that the horizontal lines defined herein are transverse and perpendicular
to their respective parallel lines P1-P8.
[0083] Referring back to Figure 25, the sprayer neck 916 is elongate-shaped, angled forward
at the lower end 922 toward the front 912 of the fluid application system 900, and
substantially disposed off-centered, toward a rear 914 of the system 900 above the
refill container 924. It is contemplated that the present embodiment provides several
advantages over other dispensing systems known in the art. For instance, it is easier
for a user to operate the fluid application system 900 than previous dispensers due
to the significantly improved ergonomic characteristics that are uniquely achieved
by the present configuration. In operation, the user's experience during a dispensing
period of the fluid application system 900 is enhanced by the present configuration,
which directly mitigates the longstanding problem of torque-related dynamics imparted
on the user's joints over a period of dispensure. In particular, such problems that
were encountered and considerably alleviated herein include wrist discomfort and other
human joint-related strains that afflict operation of other dispensing systems known
in the art. More particularly, a focus of improving the user experience herein involves
optimizing the gripping portion or member of the fluid application system 900, such
as a position of the sprayer neck 916, in a common usage situation whereby a front
container, e.g. the diluent container 926, is emptied at a faster rate than a rear
container, e.g. the refill container 924. In fact, such a system may also benefit
other sprayers that utilize a single container with two or more reservoirs or sprayers
with two or more separate containers, in which one of the containers and/or reservoirs
is emptied at a faster rate during normal usage.
[0084] Referring to Figure 30, results from an optimization analysis of the position of
the sprayer neck 916 to enhance ergonomic characteristics of the fluid dispensing
system 900 are shown. The optimization analysis was utilized to minimize forces and
torques about the user's joints, with a primary focus being minimization of the torque
force about the user's wrist. In the theoretical study, three different positions
of the sprayer neck 916 were analyzed and their torque profiles plotted. A half-filled
diluent container 926 and a full refill container 924 were assumed to simulate a typical
usage situation, in which the diluent contained in the diluent container 926 is used
up at a faster rate than the refill contained in the refill container 924.
[0085] Figure 30 shows a plot of torque about the user's wrist across various angles of
articulation of the user's arm during usage of various positions of the sprayer neck
916. Particularly, an x-axis 940 of arm articulation angles from a horizontal plane
in degrees and a y-axis 942 of the torque about the user's wrist in kg/m are provided.
A vertical line h represents a horizontal arm position, in which the arm is stretched
horizontally outward in line with a horizontal plane, such as a planar floor, and
thus is zero degrees above or below the horizontal. The vertical line h forms intersection
points 944a, 944b, 944c with a torque curve 946a measured in a forward position, a
torque curve 946b measured in an off-center position, and a torque curve 946c measured
in a rear position. It was understood that as the user rotated their arm up or down,
i.e., above or below the horizontal, a torque about the user's wrist was created.
[0086] Referring to Figures 30 and 31A-C, in one analysis the sprayer neck 916 is located
in a forward position on a fluid application system 900 as shown in Figure 31A, whereby
the sprayer neck 916 is to a greater extent disposed above the diluent container 926.
This representation is also illustrative of a sprayer neck 916 provided above one
reservoir of a multi-reservoir single container that evacuates a product to a greater
extent than the other reservoir(s). The forward position produces the torque curve
946a that intersects with the horizontal arm curve h at the intersection point 944a.
The intersection point 944a indicates that at a zero angle horizontal arm position
where the user grips the forward positioned sprayer neck 916, a torque of approximately
0.020 kg/m about the user's wrist in the horizontal position is created. The torque
increases as the user's arm is raised from the horizontal to about 55 degrees above
the horizontal where the torque climbs to about 0.035 kg/m. The torque about the wrist
then drops as the arm is continued to be raised from 55 degrees and 90 degrees above
the horizontal, where the torque drops to about 0.029 kg/m. Similarly, as the user
lowers their arm from the horizontal, where the torque starts at 0.020 kg/m, the torque
drops to zero when their arm is about 35 degrees below the horizontal. The torque
then gradually increases in an opposing direction when the arm moves from 35 degrees
below to 90 degrees below the horizontal, where the torque increases to 0.029 kg/m.
[0087] A second analysis was performed with the sprayer neck 916 located at an off-centered
position on the fluid application system 900 as shown in Figure 31B, whereby the sprayer
neck 916 is disposed to a lesser extent over the diluent container 926 and to a greater
extent over the refill container 924 or biased toward the rear 914 of the fluid application
system 900. Such representations are also illustrative of a sprayer neck 916 provided
off-centered above one reservoir of a multi-reservoir single container that evacuates
a product to a greater extent than the other reservoir(s). The off-center position
produces the torque curve 946b that intersects with the horizontal arm curve h at
the intersection point 944b, which indicates that by offsetting the sprayer neck 916
from the center of the fluid application system 900, there is zero torque about the
user's wrist in the horizontal position. The torque increases as the user's arm rises
from the horizontal to 90 degrees above the horizontal, where to about 0.033 kg/m.
As the user's arm lowers from the horizontal to 90 degrees below the horizontal, the
torque increases to about 0.033 kg/m in the opposite direction. It is noted that a
maximum torque felt by the user in the off-centered position, 0.033 kg/m, is theoretically
less than the maximum torque felt by the user in the forward position at 0.035 kg/m,
as described above.
[0088] In a third analysis, the sprayer neck 916 was disposed at a rear position of the
fluid application system 900 as shown in Figure 31C, whereby the sprayer neck 916
is disposed predominately over the refill container 924. This representation is also
illustrative of a sprayer neck 916 provided above a rear portion of one reservoir
of a multi-reservoir dispenser that evacuates a product from one reservoir more quickly
than the other reservoir(s). The rear position produces the torque curve 946c that
intersects with the horizontal arm curve h at the intersection point 944c, which indicates
that a torque of approximately 0.012 kg/m is created about the user's wrist in the
horizontal position. Moving upward on the curve 946, the torque decreases to zero
when the arm is raised about 20 degrees from the horizontal. As the user's arm continues
to be raised from 20 degrees to 90 degrees above the horizontal, the torque gradually
increases to about 0.033 kg/m. On the other hand, as the user's arm lowers from the
horizontal to about 70 degrees below the horizontal, the torque increases to a maximum
of about 0.035 kg/m. As the user's arm continues to drop from 70 degrees to 90 degrees
below the horizontal, the torque decreases from about 0.035 kg/m to about 0.033 kg/m.
It is noted that a maximum torque felt by the user in the rear position, 0.035 kg/m,
is theoretically larger than the maximum torque felt by the user in the off-center
position at 0.033 kg/m.
[0089] As such, the three positions that were analyzed indicate that the location of the
sprayer neck 916 is optimized in the off-centered position for the usage situation
where the diluent container 926 is half full and the refill container 924 is full.
The off-centered position achieves zero torque about the user's wrist at the horizontal,
zero-degree position and provides the lowest torque through the articulation angles
from the horizontal for all three positions. In a further aspect, it is understood
that as the fluid application system 900 is used and contents are depleted from the
refill container 924 and the diluent container 926, a center of gravity Cg changes
and thus requires the position of the sprayer neck 916 to change in order to achieve
a more balanced system 900 with the user's arm in the horizontal position. For instance,
in usage situations where the diluent container 926 is more full than the refill container
924, the sprayer neck 916 should be positioned biased toward the front 912 of the
fluid application system 900. On the other hand, in usage positions where the diluent
container 926 is less full than the refill container 924, the sprayer neck 916 should
be positioned biased toward the rear 914. Given the present situation where the diluent
container 926 empties faster than the refill container 924 and is therefore typically
less full than the refill container 924 during a usage period, the optimal sprayer
neck 916 positioning is biased toward the rear 914 of the fluid application system
900.
[0090] Referring now to Figure 32, an experiment to validate the theoretical analysis of
the sprayer neck 916 positioning was performed. In particular, a sprayer test rig
950 having representative components of the various elements described in the fluid
application system 900 was provided. The sprayer test rig 950 comprised a test head
952 including a test nozzle 954 and a test trigger 956 disposed toward a front side
958 of the test head 952, which opposes a rear side 960 thereof. A front test rig
side 962 and a rear test rig side 964 correspond to the sprayer test head front and
rear sides 958, 960, respectively. Further, the sprayer test head 952 was attached
to an upper handle end 966 of a sprayer test neck, or handle 968, which has a handle
body 970 extending to a lower handle end 972 of the handle 968. The lower handle end
972 was generally positioned above a refill compartment 974 and a diluent compartment
976 with a horizontal test rig diameter plate 978 disposed therebetween. In a particular
aspect, the sprayer test rig 950 had a height H of about 30.1 cm and the handle 968
had a circumference C
H of about 13.5 cm and was angled at about 100 degrees from a horizontal plane parallel
to the test rig diameter plate 978.
[0091] In the ergonomic experiment, the sprayer test rig 950 was adjustable to simulate
various user scenarios while allowing for quick adjustments in sprayer neck positioning,
angle, and form as manipulated by the moveable handle 968. Representative hands within
the 95
th percentile of US male hands and the 5
th percentile of US female hands were tested using the sprayer test rig 950 in a simulated
cleaning environment.
[0092] Initially, the sprayer test rig 950 was set up to represent a fluid application system
900 having a full refill container 924 and a full diluent container 926. The containers
924, 926 are represented by the refill compartment 974 and the diluent compartment
976, which each initially held eight washers 980a, b on posts 982a, b, respectively.
Each washer 980a, b weighed approximately 1.29 oz for a total weight of about 10.3
oz per eight washers 980a, b. The sprayer neck 916, represented as the handle 968,
was initially set at a forward position toward the front test rig side 962. Each user
participating in the experiment went through a range of motion that simulated cleaning
activities on multiple vertical and horizontal surfaces at a variety of heights and
the user's experiences were documented.
[0093] Next, the sprayer test rig 950 was modified by removing a single washer 980b from
the diluent compartment 974. Each user simulated the cleaning activity and the user's
experiences were documented. This overall procedure was repeated, continually removing
one washer 980b from the diluent compartment 974 at a time until the diluent compartment
974 was depleted. Subsequently, the handle 968 was moved closer toward the rear test
rig side 964 in 1.0 cm increments while repeating the overall testing procedure and
documenting the user's experiences.
[0094] Results from the above experiment were found to be representative of the results
from the analysis described above. In particular, as the diluent compartment 976 depleted
faster, it was found that the handle 968 needed to be adjusted toward the rear test
rig side 964 in order to accommodate the changing center of gravity Cg of the sprayer
test rig 950. Further, it was found that on average, the handle 968 provided the greatest
ergonomic satisfaction to the user at approximately 5/8 of a distance X from the front
test rig side 962 to the rear test rig side 964. In a some aspects, the rear and front
test rig sides 962, 964 correspond to outermost peripheries of the refill and diluent
compartments 974, 976, which further represent the outermost peripheries of the refill
and diluent containers 924, 926. As such, a maximum distance from one distal side
of the refill container 924 to another distal side of the diluent container 926 defines
the distance X.
[0095] Still referring to Figure 32, the next step of the ergonomic experiment involved
testing a range of sprayer neck or handle 968 shapes for comfort within the range
of 95
th percentile US male and 5
th percentile US female hands. The testing analyzed basic handle shapes including circular,
elliptical, square, and rounded corner squares, and further tested varying circumferences
C of the handles ranging from about 11 cm to 13.5 cm. Therefore, various contours
of the handle 968 were tested to find a balance that was acceptable to the 95
th percentile US male and 5
th percentile US female hands. A geometry profile was created in view of male respondents'
indication that a round handle yielded high performance and an elliptical handle yielded
moderate performance, and in view of female respondents' indication that the elliptical
handle yielded high performance and the round handle yielded moderate performance.
Both male and female respondents agreed on a trigger height and a heel type of the
handle 968, which preferably has a wide heel 984 to better support the user's hand
without obstructing the user's grip. In particular, the optimized trigger height T
H was approximately 6.5 cm and the optimized handle circumference C
H was approximately 11.0 cm, with the heel 984 abutting an upper portion of the user's
hand. As such, a trigger height T
H is between about 6.0 cm to about 7.0 cm, and alternatively between about 6.2 cm to
about 6.8 cm, and still alternatively between about 6.4 cm to about 6.6 cm. A handle
circumference C
H is between about 10.0 cm to about 12.0 cm. Alternatively, the handle circumference
C
H is between about 10.4 cm to about 11.6 cm. Still alternatively, the handle circumference
C
H between about 10.8 cm to about 11.2 cm.
[0096] In further ergonomic testing, practical weight distribution and handle positioning
were analyzed at a higher degree of granularity. It was assumed that the sprayer test
head 952 must be horizontal to an x-axis defined by the test rig diameter plate 978
and the sprayer test rig 950 must balance when resting an underside of the sprayer
test head 952 on the web of the user's hand. Further, the handle 968 was set at an
angle of 100 degrees from a horizontal plane defined by the distance X, it being understood
that a 100 degree angle is the optimal angle for spraying a vertical surface and maintaining
a neutral wrist posture. It was also understood that since the refill container 924
and the diluent container 926 would rarely be full at the same time, the full situation
would not solely drive the handle 968 location along the distance x. Furthermore,
it was assumed that the optimal handle 968 location would be between the center of
gravity Cg1 of the diluent compartment 974 and the center of gravity Cg2 of the refill
compartment 976, since the refill fluid would be depleted more slowly than the diluent
fluid. Further, it was assumed that when the diluent level became low, it would be
quickly replenished to continue operation.
[0097] In the additional test, the user picked up the sprayer test rig 950 having a fixed
handle 968 angle A at 100 degrees, 10 washers 980a, b in each of the refill and the
diluent compartments 976, 976, respectively, and a variable handle 968 location along
the distance x. First, the center of gravity Cg and balance of the sprayer test rig
950 were evaluated when the rig 950 was lifted to simulate directly spraying a vertical
surface. Second, the user simulated spraying motions by swinging their arm slowly
from a 45 degree angle below a horizontal to a 45 degree angle above a horizontal
while considering balance and comfort throughout. Third, one diluent washer 980b was
removed and the first and second steps were repeated. Then, the handle 968 location
was changed by incremental centimeters and the above three steps were repeated. Further,
the distance X represented a sprayer test rig width of 15.5 cm, and the center of
gravity Cg of the sprayer test rig 950 was approximately a linear distance C of 2.5
cm from a base 986 of the rig 950.
[0098] It was contemplated that since the refill container 974 is depleted less quickly
than the diluent container 976, the handle 968 of the sprayer test rig 950 should
be located off-center and more toward the center of gravity Cg2 of the refill container
924 represented by the refill compartment 974. Further, it was rationalized that since
the diluent container 926 rarely remains empty, even as the refill container 924 slowly
depletes, the optimal handle 968 location is located between the center of gravity
Cg of the sprayer test rig 950 and the center of gravity Cg2 of the refill compartment
976.
[0099] Given the above ergonomic experiments and analysis, it was found that an optimal
sprayer test rig height H is in the range of about 75 mm to about 85 mm. Further,
since the refill container 924 is depleted less quickly than the diluent container
926, the handle 968 should be located off-center and biased toward the rear of the
sprayer at an approximate location of 5/8 the length of the refill and the diluent
reservoirs as measured by the distance X from a front of the sprayer test rig 950.
As such, an optimized handle location HL is about at 5/8*X, or about 9.7 cm for a
horizontal distance x = 15.5 cm measured from the front test rig side 962 for a system
in which the diluent compartment 976 empties faster than the refill compartment 974.
[0100] Even further, the ergonomic experiments revealed that handle circumference, sprayer
test rig to trigger circumference, and engagement of the hand against the heel were
highly valued. In an optimized configuration, the handle circumference C
H is about 11 cm to accommodate the 5
th percentile US female hands and the lower handle end 972 is larger and gently tapered
inward to guide the user's hand into the heel 984. Further, it was revealed that the
circumference CBT around the back of the handle 968 to the front of the test trigger
956 needs to be about 15 cm to about 18 cm in order to accommodate the 5
th percentile US female hand. Still further, the heel 984 also distributes force about
the top of the index finger, web of the hand and the thumb, without creating pressure
points for populations with hand sizes ranging from the 5
th percentile US female to the 95
th percentile US male hand sizes.
[0101] As shown in Figures 33A-C, a plot showing the behavior of the dynamic center of gravity
for the fluid application system 900 is shown with arbitrary units on the x-y axis.
The arbitrary units may change with actual dimensions of the fluid application system
900 and diluent to concentrate mix ratios, however, the underlying x-y axis relationships
remain unchanged. In particular, Figures 33A-C show that as the diluent container
926 is used at a faster rate than the refill container 924, the center of gravity
Cg of the fluid application system 900 generally moves rearward from Cg to a final
center of gravity Cgf ' along a trajectory T. It is noted that the trajectory T can
be used to extrapolate additional centers of gravity for intervening fill levels of
the diluent reservoir 926.
[0102] In Figure 33A, when fluid levels of the containers 924, 926 are full and approximately
equal, otherwise known as a full-full state or pre-use state, the center of gravity
Cg is centered about the distance X, which is taken from a diluent outer periphery
992 to a refill outer periphery 994. In particular, the center of gravity Cg is initially
located at position Xg, whereby Xg = X/2. This position, Xg, may also correspond to
an optimal sprayer neck 916 location along the distance X during the full state.
[0103] Figure 33B shows that when the fluid level of the diluent container 926 is about
halfway full and the refill container 924 is full, otherwise known as a half full
state or in-use state, the center of gravity Cg has migrated rearward toward a minimum
on the trajectory T to point Cg' at point Xg' along the distance X. It is noted that
the center of gravity Cg' is lower along a vertical y-axis of the fluid application
system 900. It is contemplated that the half full state is a common usage situation
for the fluid application system 900 when deployed.
[0104] Figure 33C illustrates an empty-full state or empty state where the fluid level of
the diluent container 926 is substantially depleted while the refill container 924
is still full. In this scenario, the center of gravity Cg' rises along the trajectory
T from Cg' to Cgf at a distance Xgf from the diluent outer periphery 992. The final
center of gravity Cgf may be close or equal to the center of gravity of the full refill
container 924.
[0105] It is noted that the above dynamic changes in centers of gravity along the trajectory
T are directly related to the faster depletion rate of the diluent container 926 compared
to the refill container 924. For instance, and merely by way of example, the faster
depletion rate of the diluent container 926 is reflected in various diluent to refill
mix ratios that are provided during normal operation, including diluent to refill
mix ratios between about 1.5:1 to about 100:1. Preferably, the diluent to refill mix
ratio is between about 10:1 to about 75:1, and more preferably between about 20:1
to about 50:1, and most preferably between about 24:1 to about 32:1. In some embodiments,
it is contemplated that the fluid level of the diluent container 926 can drop to approximately
50 percent of the fluid level of the refill container 924. As such, a dynamic imbalance
exists and the position of the sprayer neck 916 becomes more or less favorable to
a user with the changing center of gravity Cg of the fluid application system 900
during use. The imbalances may create a range of continuously-changing favorable positions
for the sprayer neck 916 in such a dynamic situation.
[0106] In particular, initially the optimal sprayer neck 916 position coincides with Xg
to provide a balanced system when both the refill container 924 and the diluent container
926 are full. After one or more uses, whereby the diluent container 926 is emptied
faster than the refill container 924, the center of gravity of the system migrates
to a new center of gravity Cg' positioned at Xg'. It can be appreciated that the preferred
location for the sprayer neck 916 migrates from a first dispense to a second dispense
by an absolute distance of approximately Xg'-Xg starting from a half of the distance
X due to changing centers of gravity from Cg to Cg'. In particular, the first dispense
occurs during a state of full refill and diluent containers 924, 926 while the second
dispense corresponds to a half full diluent container 926 and a generally full refill
container 924. It is further contemplated that the use of the term second dispense
does not necessarily limit the same to the immediately subsequent spraying operation,
but may be inclusive of one or more sprays to reach a half full or otherwise non-full
state. The dispensing period between the first dispense and the second dispense corresponds
to a typical, most common usage state of the system, and thus the position of the
sprayer neck 916 can be optimized for those uses between and inclusive of the first
dispense and the second dispense (and any of the plurality of dispenses occurring
therebetween). Therefore, the sprayer neck 916 location can be optimized for that
particular common usage period at a distance of X that is between (X/2) to Xg'. In
one aspect, it is contemplated that the lower end 922 of the sprayer neck 916 is located
beyond at least 50 percent of the distance X taken from the front 912 of the fluid
application system 900. Similarly, in a different situation, where a common usage
period spans from the full-full state to the empty-full state, then an optimal distance
for the sprayer neck 916 is between (X/2) to Xgf. Furthermore, it is noted that the
same types of insights can be gained in systems where one reservoir is slightly larger
than the other, such that at the end of a normal usage period, the remaining fluid
level in the larger level is still less than in the remaining reservoir. For instance,
it is contemplated that the diluent container 926 may be 12 oz. while the concentrate
container 924 may be 10 oz.
[0107] Further, in another embodiment, it is contemplated that the diluent container 926
includes a weight represented by the value X1 in a full, pre-use state and a refill
container 924 includes a weight of the constituent components represented by a value
Y in a full, pre-use state. During a use state the percent change in weight of the
constituent components of the diluent and refill containers 926, 924 may be expressed
by the equation % ΔX1 > % ΔY. Further, it is contemplated that the weight of constituent
components of the diluent and refill containers 926, 924 during a use state may be
expressed by the equation X1 < Y. In a different embodiment, it is contemplated that
the diluent container 926 has a weight and volume represented by the values X1 and
V, respectively, in a full, pre-use state and the refill container 924 includes a
weight and volume represented by the values Y and W, respectively, in a full, pre-use
state. It is contemplated that after the emission of the product during a use state,
the constituents may be characterized by X1 < Y and/or V < W. Further, after emission
of the product during a use state, the constituent components of the diluent and refill
containers 926, 924 may be characterized by % ΔX1> % Δ Y and/or % ΔV > % ΔW. In a
different embodiment, it is contemplated that in a single use, the emitted product
comprises a volume V
1 of the constituent components of the diluent container 926 and a volume W
1 of the constituent components of the refill container 924, wherein V
1 > W
1. In some embodiments, the V
1 is at least 10 times greater than W
1. In other embodiments, V
1 is at least 30 times greater than W
1.
[0108] The fluid application systems described herein are also advantageous over common
dispensers known in the art due to the unique product flow control mechanism provided
with the refill container 924. Specifically, a single fluid application system can
dispense a plurality of different diluent to chemical mix ratios with significant
ease. In particular, the present fluid application system 900 utilizes the non-pressurized
refill container 924 to regulate the controlled outflow of product or chemicals contained
therein to be drawn upward into the sprayer head 902.
[0109] Figure 34 is a cross-sectional view of the refill container 924, which is similar
to the previously described Figure 17. The chemical container 924 is generally cylindrical-shaped,
although other shapes can be contemplated as described above. The chemical container
924 defines a base 1010, which may be flat for engaging a resting surface, such as
a table-top. However, the present embodiment includes a convex center 1012 that protrudes
as a slight dome-shaped structure into an interior cavity 1014 of the container 924.
The base 1010 extends upwardly about its periphery to define a curved bottom edge
1016 or a convex edge that protrudes convexly away from the interior cavity 1014.
The curved bottom edge 106 engages or is integrally formed with a sidewall 1018 at
a lower sidewall end 1020.
[0110] The sidewall 1018 continuously extends to an upper sidewall end 1022 distal from
the base 1010. In the present embodiment, the sidewall 1014 tapers continuously inwardly
and gradually from the lower sidewall end 1020 to the upper sidewall end 1022. Therefore,
a cross-section of the sidewall 1018 and the internal cavity 1014 has a continuously
varying shape and volume, respectively.
[0111] A concave sidewall 1024 is disposed immediately above the upper sidewall end 1022
and is characterized by an inwardly sloped or concave portion. In the present embodiment,
the sidewall 1018 has a generally smooth radius of curvature of about 0.5 cm to about
2.0 cm. Further, a cross-sectional diameter taken about the particular portion of
the concave sidewall 1024 region is approximately 3/5ths or less of the cross-sectional
diameter taken about the particular portion of the sidewall 1014 region. It is contemplated
that the concave sidewall 1024 does not define a continuously-varying cross-sectional
area, as it may project in a straight line at ends thereof. Further, it is contemplated
that the concave sidewall 1024 has a vertical extent that is shorter than the upward
extent of the sidewall 1018.
[0112] Still referring to Figure 34, the upper concave end 1028 is further attached to a
stepped portion 1030 that comprises a vertical wall 1032 extending upwardly to a transverse
horizontal wall 1034 that extends radially inwardly around a center of the refill
container 924. A cylindrical wall 1036 extends upwardly from an innermost end of the
horizontal wall 1034 and defines an opening 1038 that is circumscribed by a peripheral
flange 1040 having a protruding wall 1042 angled outwardly from the opening 1038.
As described previously, the peripheral flange 1040 is adapted to engage attaching
means provided in the fluid application system 900. It is contemplated that the cylindrical
wall 1036, the peripheral flange 1040, the step 1030, and at least a portion of the
concave sidewall 1024, such as the upper concave end 1028, defines a mounting cup
1044 of the chemical container 924.
[0113] Referring now to Figures 34 and 35, in operation, the mounting cup 1044 mounts the
chemical container 924 to the remainder of the fluid application system 900 in various
methods as described above, and further mounts fluid dispensing components to the
chemical container 924. For instance, the cylindrical wall 1036 is bounded at its
lower end by a circular, horizontal plate 1046 that has a central hole 1048 which
snugly receives therethrough an upper end 1050 of a valve stem 1052. The central hole
1048 defines a top of a downwardly extending central well 1054 which retains a valve
body 1056 therein. In particular, the central well 1054 defines a lower ridge 1058
that engages underneath a corresponding upper ridge 1060 of the valve body 1056. The
valve body 1056 provides a closed cavity 1062 adapted to receive the valve stem 1052
and a spring 1066 therein to bias the valve stem 1052 upward into a closed position.
In particular, in the closed position a plurality of stem orifices 1068 disposed about
a lower end of a wall 1070 that defines a cylindrical channel 1072 of the valve stem
1052 are engaged with the stem gasket 1064, which prohibits product from entering
the channel 1072. When the refill container 924 is activated and the valve stem 1052
is depressed downward toward the closed cavity 1062, the stem orifices 1068 are exposed,
opened, and product is permitted to enter the cylindrical channel 1072 of the valve
stem 1052.
[0114] Still referring to Figure 34, a valve retainer, otherwise known as a valve retaining
well 1074, is disposed adjacent to and radially offset from the valve stem 1052. The
valve retaining well 1074 defines an off-centered hole 1076 on the horizontal plate
1046, also known as an upper plate. The off-centered hole 1076 provides the downwardly
extending valve retaining well 1074 having an inwardly protruding lip 1080 for engaging
a venting valve 1082, and particularly for engaging an underside of a valve ridge
1084, which is a peripheral ring about the venting valve 1082. As described above
previously, the venting valve 1082 can comprise a one-way valve, such as a duckbill
valve, or a two-way valve, such an integrated umbrella and duckbill valve. In a different
aspect, the venting valve 1082 and its retaining structures on the horizontal plate
1046 are replaced by a porous membrane portion.
[0115] In a particular embodiment, the valve body 1056 defines a central passageway 1086
that is coaxially aligned with the cylindrical channel 1072 of the valve stem 1052.
The central passageway 1086 is defined by a valve body elongate channel 1088 that
has a valve body intake port 1090 at a central passageway lower end 1094 and a valve
body outlet port at a central passageway upper end 1096. Further, the central passageway
upper end 1096 defines a converging flow path 1098, such as tapering sidewalls as
described previously above, to converge flow toward the valve body outlet port 1092.
It is contemplated that a cross-sectional area of the valve body outlet port 1092
is less than a cross-sectional area of the valve body intake port 1090. Further, it
is contemplated that a product intake conduit 1100 is press-fit over the central passageway
1086 of the valve body 1056 to communicate a volume of product from a lower orifice
of the conduit 1100, referred to as a product ingress 1102 upward to an upper orifice
of the conduit 1100, referred to as a product egress 1104, and further on to the valve
stem 1052.
[0116] Referring to Figures 34-36, in some embodiments it is contemplated that the product
intake conduit 1100 comprises a product dip tube 1106 in fluid communication with
a restriction region R that is downstream of the tube 1106 and in some embodiments
also inclusive of the tube 1106. A flow restrictor 1108 is provided in the restriction
region R for imparting flow restraints on a flow of product, or product stream, therethrough.
Such flow restraints may cause changes in flow rate and pressure of the product stream
traveling therethrough. It is contemplated that the flow restraints applied in the
restriction region R assist in achieving particular mix ratios of the diluent to the
chemical when expelled from the fluid application system 900. Further, it is noted
that the restriction region R is provided to illustrate a general section of the present
fluid application system 900 where a flow restriction occurs, and that other flow
restrictions can also occur at areas within or outside of the restriction region R.
[0117] As shown in Figure 35, the restriction region R is located on an underside of the
mounting cup 1044. Particularly, the restriction region R is located at an area of
flow that is upstream of the valve stem 1052. More particularly, the restriction region
R is located near the valve body 1056 and in some embodiments the region R is inclusive
of the valve body elongate channel 1088. It is contemplated that the flow restrictor
1108 provided at the restriction region R is a physical feature that is adapted to
impart a flow characteristic on the product stream to ultimately control an amount
of product that enters the previously described mixing chamber 343 of the previously
described fluid manifold 340. As such, the restriction region R is applied upstream
of the fluid manifold 340 and also the valve stem 1052, which is in the flow pathway
from the valve body 1056 to the fluid manifold 340. By controlling the flow characteristics
of the product stream, it is possible to achieve a desired diluent to chemical mix
ratio, which is expelled from the nozzle 904. Further, by implementing the function
of controlling the product stream at the refill container 924, the fluid application
system 900 is versatile in achieving a variety of different diluent to chemical mix
ratios simply by engaging different refill containers 924 that yield the desired mix
ratio. As such, the refill container 924 described herein provides a flow control
mechanism that is independent of other mechanisms provided downstream of the refill
container 924. Therefore, the fluid application system 900 is significantly improved
over traditional multi-reservoir dispensers that instead provide flow control mechanisms
downstream of refill reservoirs within the dispensers, whereby their mix ratio is
a single mix ratio that is pre-set by the dispenser itself. On the other hand, the
fluid application system 900 can expel different chemicals and different diluent to
chemical mix ratios by simply changing out the refill containers 924 to other refill
containers having other flow restrictions and/or chemicals.
[0118] Turning to Figure 36, a schematic diagram illustrates a portion of a flow pathway
surrounding the restriction region R. In particular, the restriction region R includes
the flow restrictor 1108 that is downstream of an entry portal 1110 and is upstream
of an exit portal 1112. The entry portal 1110 and the exit portal 1112 define positions
in the flow pathway where an initial chemical stream Ci enters the restriction region
R and a restricted chemical stream Cr exits the region R, respectively. As such, the
entry and exit portals 1110, 1112 can change and are dependent on the configuration
of the flow restrictor 1108. The initial chemical stream Ci is guided into the entry
portal 1110 by the chemical dip tube 1106. The restricted chemical stream Cr leaving
the restriction region R is subsequently guided into the valve stem 1052. In particular,
it is contemplated that the initial chemical stream Ci is restricted by a portion
of the valve body 1056 and/or a capillary tube 1114, which provided together or as
alternatives are considered the flow restrictor 1108 of the present embodiment. Further,
it is noted that the components upstream of the valve stem 1052 are collectively referred
to as the chemical intake conduit 1100.
[0119] Turning now to Figure 37, the present embodiment of the flow restrictor 1108 comprises
a portion of the valve body 1056 as shown in greater detail within the restriction
region R. In particular, the flow restrictor 1108 comprises a non-converging channel,
hereon referred to as the central passageway 1086; a converging channel, hereon referred
to as the converging flow path 1098; and a secondary non-converging channel 1118 that
has an upstream terminating end defined by the valve body outlet port 1092. In the
present embodiment, the entry portal 1110 to the flow restrictor 1108 coincides with
the valve body intake port 1090 and the export portal 1112 coincides with the valve
body outlet port 1092. Further, the chemical dip tube 1106 is press-fit over an outer
surface 1120 of the valve body elongate channel 1088. The outer surface 1120 provides
an angled outer surface 1122 that tapers inwardly to define the valve body intake
port 1090. It is contemplated that the angled outer surface 1122 eases assembly of
the chemical dip tube 1106 onto the valve body elongate channel 1088 by allowing it
to slide on into a sealing-fit.
[0120] In the present embodiment, the central passageway 1086 is a straight, hollow, tubular
passageway that receives and alters a flow rate and/or pressure of the initial chemical
stream Ci. It is contemplated that the central passageway 1086 has straight longitudinal
sidewalls 1124 with an axial length L
N, whereby a portion of the longitudinal sidewalls 1124 comprise the valve body elongate
channel 1088. A downstream portion of the longitudinal sidewalls 1124 coincide with
a valve body base wall 1126, which is transverse to the valve body elongate channel
1088 extending downwardly therefrom. Further, the central passageway 1086 comprises
a radial diameter D
N that is uniform throughout the extent of the passageway 1086. In the present embodiment,
the central passageway 1086 or the non-converging channel comprises an axial length
of between about 5 mm to about 8 mm and preferably about L
N = 7.7 mm. The internal radial diameter D
N is between about 1 mm to about 2 mm and preferably about D
N = 1.5 mm. The valve body elongate channel 1088 surrounding the central passageway
1086 comprises a cylindrical length Lo between about 4 mm to about 7 mm and preferably
about Lo = 5.0 mm from the valve body base wall 1126 to the angled outer surface 1122.
The angled outer surface 112 comprises an axial length L
A of between about 0.5 mm to about 2.5 mm, and preferably about L
A = 1.5 mm. For comparison, the chemical dip tube 1106 comprises an internal diameter
D
DT between about 2.5 mm to about 4 mm and a length L
DT between about 15 mm to about 25 mm. Preferably, the length L
DT = 19.1 mm and the diameter D
DT = 3.1 mm. As such, at the entry portal 1110, the cross-sectional flow diameter is
decreased by about (D
DT - D
N)/ D
DT, or 50 percent from that provided by the chemical dip tube 1106 to restrict the initial
chemical stream Ci. It is contemplated that other changes in the cross-sectional flow
diameter at the entry portal 1110 can be realized ranging from between about a 25
percent decrease to about an 80 percent decrease depending on the amount of flow restriction
desired.
[0121] Still referring to Figure 37, the central passageway 1086 extends upwardly toward
the converging channel entrance 1116, whereupon an angled wall 1128 converges inwardly
from an inner surface of the central passageway 1086 to define the converging flow
path 1098. It is contemplated that the converging flow path 1098 defines a smallest
diameter Dc between about 0.20 mm to about 0.60 mm and preferably about Dc = 0.40
mm. Further, the converging flow path 1098 defines an axial length Lc between about
1.0 mm to about 2.0 mm, and preferably about Lc = 1.2 mm.
[0122] The secondary non-converging channel 1118 is disposed between the converging flow
path 1098 and the valve stem 1052. It is contemplated that the non-converging channel
1118 has straight sidewalls 1130 extending upwardly at an axial length L
N2 at about 0.10 mm to about 0.50 mm, and preferably L
N2 = 0.25 mm. A radial diameter taken across the secondary non-converging channel 1118
is uniform and approximately the same as the smallest diameter Dc defined above by
the converging flow path 1118. As such, at the exit portal 1112, the cross-sectional
flow diameter is decreased by about (Dc - D
N)/ D
N, or about 70 percent from that provided by the central passageway 1086.
Computational Fluid Dynamics Analysis
[0123] A computational fluid dynamics (CFD) analysis was performed on the fluid application
system 310 using the fluid geometry and boundary conditions shown in Figure 38. The
results of six CFD iterations are shown in Table 1 below. A variety of desired mixing
ratios can be achieved through metering methods based on valve cracking pressures
within the fluid application system ranging from a minimum of 0 kPa to a maximum of
6.89 kPa (1 psi) and varying restriction sizes of the concentrate line. Looking at
the non-limiting iterations in Table 1, (1) to achieve a mixing ratio of 9.1 or less
during a minimum overall flow rate of 0.5 milliliters per second (mils), the pressure
drop from the tip of the concentrate line to the mixing chamber should be controlled
to -8.846 kPa (-1.283 psi) or less; (2) to achieve a mixing ratio of 33.9 or less
during a minimum overall flow rate of 2.5 mils, the pressure drop from the tip of
the concentrate line to the mixing chamber should be controlled to -16.347 kPa (-2.371
psi) or less; (3) to achieve a mixing ratio of 63.4 or less during a minimum overall
flow rate of 0.5 mils, the pressure drop from the tip of the concentrate line to the
mixing chamber should be controlled to -8.860 kPa (-1.285 psi) or less; (4) to achieve
a mixing ratio of 285 or less during a maximum overall flow rate of 2.5 ml/s, the
pressure drop from the tip of the concentrate line to the mixing chamber should be
controlled to -10.315 kPa (-1.496 psi) or less; (5) to achieve a mixing ratio of 1.4
or less during a maximum overall flow rate of 2.5 mils, the pressure drop from the
tip of the concentrate line to the mixing chamber should be controlled to -9.487 kPa
(-1.376 psi) or less; (6) to achieve a mixing ratio of 11.8 or more during a maximum
overall flow rate of 2.5 mils, the pressure drop from the tip of the concentrate line
to the mixing chamber should be controlled to -0.531 kPa (-0.077 psi) or more; and
(7) to achieve a mixing ratio of 9.4 or less during a maximum overall flow rate of
3.5 mils, the pressure drop from the tip of the concentrate line to the mixing chamber
should be controlled to -1.262 kPa (-0.183 psi) or less. The maximum mixing ratio
could be controlled to be unlimited. At an overall flow rate from 0.5 mils to 3.5
mils and a diluent to chemical mixing ratio from 1:1 to 1:300, the pressure drop through
the concentrate line ranges from -0.531 kPa to -16.347 kPa (-0.077 psi to -2.371psi),
and the flow rate of the concentrate varies from 0.008 mils to 1.05 mils, and the
pressure drop through the water line ranges from -14.582 kPa to -7.081 kPa (-2.115
psi to - 1.027psi).
[0124] Thus, the present invention provides an improved chemical application system. Among
other things, the chemical application system automatically dilutes a concentrate
refill with water without use of a venturi. The chemical application system mixes
chemical on demand and allows the consumer to use a multitude of different refill
chemistries that require different dilution ratios with no adjustments. The refill
mates with the sprayer device of the chemical application system. The chemical application
system is portable and may include a manual pump, or a pump having a motor powered
by batteries. The dilution rate can be controlled by a restriction orifice in the
dip tube in the chemical refill container. The fluid application system preferably
provides the same dilution ratio from a concentrate refill when the same concentrate
refill is used with a manual pump or a pump having a motor powered by batteries.
[0125] Although the present invention has been described in detail with reference to certain
embodiments, one skilled in the art will appreciate that the present invention can
be practiced by other than the described embodiments, which have been presented for
purposes of illustration and not of limitation. Therefore, the scope of the invention
should not be limited to the description of the embodiments contained herein.
INDUSTRIAL APPLICABILITY
[0126] The present invention provides a fluid application system for mixing a chemical with
a diluent and spraying a mixture of the chemical and the diluent. The fluid application
system includes a sprayer assembly, a diluent reservoir, and a complementary system
of one or more fluid chemical concentrate refills, each including a chemical dip tube
with a restriction orifice that provides for a proper dilution ratio of the diluent
and chemical concentrate.
TABLE 1
Computational Fluid Dynamics Iterations |
Iteration # |
Flow rate (mils) |
Restriction size of Concentrate line (in) |
Water Static Pressure kPa (psi) |
Concentrate Static Pressure kPa (psi) |
Umbrella Manifold Pressure kPa (psi) |
Pressure inside the mixing chamber kPa (psi) |
Water Mass Flow Rate (kg/s) |
Concentrate Mass Flow Rate (kg/s) |
Water Line Pressure drop kPa (psi) |
Concentrate line pressure drop kPa (psi) |
Ratio |
1 |
0.5 |
0.006 |
-0.800 (-0.116) |
0.97 (0.14) |
6.89 (1.0) water, 0 Concentrate |
-7.881 (-1.143) |
0.000452942 |
0.0000497404 |
-7.081 (-1.027) |
-8.846 (-1.283) |
9.1 |
2 |
2.5 |
0.006 |
-0.800 (-0.116) |
0.97 (0.14) |
6.89 (1.0) water, 0 Concentrate |
-15.382 (-2.231) |
0.002428440 |
0.0000716359 |
-14.582 (-2.115) |
-16.347 (-2.371) |
33.9 |
3 |
0.5 |
0.003 |
-0.800 (-0.116) |
0.97 (0.14) |
6.89 (1.0) water, 0 Concentrate |
-7.893 (-1.145) |
0.000492943 |
0.0000077741 |
-7.095 (-1.029) |
-8.860 (-1.285) |
63.4 |
4 |
2.5 |
0.003 |
-0.800 (-0.116) |
0.97 (0.14) |
6.89 (1.0) water, 0 Concentrate |
-9.349 (-1.356) |
0.00249144 |
0.0000087292 |
-8.549 (-1.24) |
-10.315 (-1.496) |
285.4 |
5 |
2.5 |
0.023 |
-0.800 (-0.116) |
0.97 (0.14) |
6.89 (1.0) water, 0 Concentrate |
-8.522 (-1.236) |
0.00145347 |
0.00104653 |
-7.722 (-1.12) |
-9.487 (-1.376) |
1.4 |
6 |
2.5 |
0.023 |
0.97 (0.14) |
-6.89 (-1) |
0 water, 0 Concentrate |
-7.426 (-1.077) |
0.00230461 |
0.000195343 |
-8.391 (-1.217) |
-0.531 (-0.077) |
11.8 |
7 |
3.5 |
0.023 |
0.97 (0.14) |
-6.89 (-1) |
0 water, 0 Concentrate |
-8.156 (-1.183) |
0.00315962 |
0.000337613 |
-9.122 (-1.323) |
-1.262 (-0.183) |
9.4 |
Iterations 1, 2, 3, 4, 5,and 7 are for minimum possible mixing ratio. Iteration 6
is for maximum possible mixing ratio.
•All analyses assume the chemical density and viscosity are the same value as water. |